PerTronix JBA Exhaust 1960S - Manual (Page 3)

3. For P/N 1960,1960-1:2500 2wd and 1500 4wd. The Y-Pipe needs to be cut from the Cata-
lytic Converter. This requires the Y-Pipe / Catalytic Converter assembly to be removed from the
vehicle. This requires the transmission cross member to be removed. Support the transmission;
remove the four bolts, and the two nuts on the trans mount. Drop cross member out. Disconnect
exhaust from exhaust manifolds. Remove the muffler assembly from the Catalytic Converter
/Y-Pipe assembly. Remove Catalytic Assembly from vehicle. Temporarily re-install trans cross
member.
For P/N 1960-2:2500 4wd. The Drivers side connector pipe unbolts. The Passenger side must be
cut approximately 9” in front of the weld on the Catalytic Converter. The replacement pipe will
slip on the original exhaust pipe and needs to be welded.
4. Remove the nuts attaching the heat shields to the manifolds. Remove the manifolds. (On
2500 4x4 models, it is necessary to remove the motor mount brackets from the engine. Support
the engine; remove the four bolts attaching the brackets to the engine, remove the through bolt,
and drop mount out of the frame.)
5. Using a gasket scraper, remove all carbon deposits and high spots from head surface.
6. Using the supplied gaskets and fasteners install the new headers. Be sure to prepare the new
header bolts by applying a small amount of anti-seize to the threads before installing. The driv-
er’s side header will have two open unused holes. If removed, re-install motor mounts.
7. Cut the stock Y-pipe from the converter directly in front of the weld.
8. Connect the new Y-pipe to the headers using the hardware supplied. Trial fit the converter to
the Y-pipe, insert into the muffler assy. Correct any gaps and misalignment, tack weld the Y-
pipe to the converter. Remove and weld completely then reinstall. At this time apply a O2 sen-
sor safe high temperature sealer to collector domes of the new headers.
9. Re-secure trans cross member.
10. Check to make sure there is adequate clearance on plug wires, battery cables, wire looms,
brake lines, coolant lines, etc.
11. Re-connect battery cables.
12. Recheck everything!
13. Start the engine and let it warm up. Check for leaks. Shut engine off and let it cool down.
Check to make sure all fasteners are tight.
14. We recommend that you re-torque the fasteners on the headers after approximately 100
miles of driving. All tubular headers require maintenance including periodically checking and
retightening of the header bolts.