PerTronix Dougs Headers D6659 - Manual

Part No. 0110-003038
Page 1
rev.1 11-19-13 DSL
HEADER INSTALLATION INSTRUCTIONS
D6659
2004-2005 2&4 W/D FORD PICK-UP 5.4L 3 VALVE
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. Remove both front wheels.
4. Lay a protective covering over brakes and spindles so as not to get them dirty.
5. Remove the inner fender panels.
6. Apply penetrating oil to all nuts and bolts to be removed.
7. Remove all nuts and bolts and lower the sway bar out of the way.
8. Remove the first and second exhaust hanger brackets.
9. Support the rear of the transmission and remove the transmission cross member.
10. Disconnect the factory
“Y” pipe from the exhaust manifolds and the rest of the system.
11. Disconnect all the wires from the starter and then remove the starter.
Corporate Office: PerTronix Inc. 440 E. Arrow Highway, San Dimas, California 91773 * Phone 909.599.5955 * FAX 909.599.6424 * www.dougsheaders.com