PerTronix Dougs Headers D6621 - Manual

Part No. 0110-003036
Page 1 of 3
rev1 11-19-13 DSL
HEADER INSTALLATION INSTRUCTIONS
D6620 & D6621
1999 - 2002 Ford F250/F350 Pickups and Excursions 6.8L V10
PART NUMBER: D6620 & D6621
PerTronix
©
thanks you for choosing
DOUG’S HEADERS, the best fitting, highest quality header on the market. In
order to realize the full potential of our good fit, please read and understand these instructions completely prior to starting work.
CHECK TO MAKE SURE YOU RECEIVED THE PROPER PARTS FOR YOUR APPLICATION. THE HEADER NUMBER WILL
BE STAMPED ON THE ENGINE FLANGE. IF YOU ARE UNSURE YOU HAVE RECEIVED THE PROPER PARTS CALL
BEFORE YOU START WORK.
BE SURE TO WORK SAFE! WHENEVER YOU WORK UNDER THE VEHICLE BE SURE THAT IT IS LOCATED ON LEVEL,
SOLID GROUND AND IS SUPPORTED BY ADEQUATE SAFETY STANDS!
REMEMBER: HOT ASPHALT WILL NOT SUPPORT MOST JACK STANDS!
Many factors affect the installation of headers, some of which are broken or aftermarket motor mounts, accidents that impact the
configuration of the frame, and/or the installation of different engines or aftermarket cylinder heads. Most installations require
some welding. If you are uncomfortable with welding operations, we recommend that you contact a professional exhaust
system specialist to install your new headers.
Attention Customers breaking in new engines: Due to the extreme heat generated during the break-in process, the
appearance of the ceramic coating may be altered in certain areas. The protection characteristics and thermal barrier properties
of the coating is never compromised. It is recommended that a cast iron manifold or old set of headers be used for this process.
Notice: The coating of these headers can be marred or scratched during installation. If the header needs to be returned and is
damaged, you will be charged for recoat.
DISASSEMBLY
1. Disconnect the negative battery cable from the battery.
2. If a car lift is not available, raise the vehicle 2 feet or higher and support it with
adequate safety stands. Make sure the vehicle is on a flat solid surface and is stable.
3. Apply penetrating oil to all nuts and bolts to be removed.
4. Remove both front wheels.
5. Unbolt and remove the front inner fender panels. There are various electrical
connectors as well as some other components that must be removed in order to
facilitate the removal of these panels. There is no need to disconnect any of these
components. They can remain in place and be reinstalled during the assembly process.
6. Unplug the O
2
(oxygen) sensor wires and remove the O
2
sensors. Use care to not
damage the wire or sensors. Do not lose the gasket.
Corporate Office: PerTronix Inc. 440 E. Arrow Highway, San Dimas, California 91773 * Phone 909.599.5955 * FAX 909.599.6424 * www.dougsheaders.com