JBA 1688S Performance Exhaust Cat4ward Headers Installation Guide

June 9, 2024
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JBA 1688S Performance Exhaust Cat4ward Headers

JBA-1688S-Performance-Exhaust-Cat4ward-Headers-PRODUCT

PERTRONIX PERFORMANCE BRANDS EMISSIONS CODES
This product has been granted a California Air Resources Board (CARB) Executive Order (EO Number) Exemption. It is 50 State Legal when installed on the Specified vehicle per the Manufacturer’s Current Application Guide, the CARB EO and Installation Instructions.

AWARNING:
This product can expose you to chemicals including Lead, Nickel, Cadmium and Chromium which are known to the State of California to cause cancer and birth defects or other reproductive harm. For more information go to www.P65Warnings.ca.gov

Installation

PLEASE READ BEFORE PROCEEDING
PerTronix® thanks you for choosing a JBA Performance Exhaust Product. To realize the potential of JBA’s engineering and excellent fit, Please Read and Understand these instructions completely prior to starting the installation.

Check that you received all the parts listed on the parts list, if you have any concerns, please contact PerTronix before continuing. Headers will have the part number stamped in the flange.  Work Smart – Work Safe! Most Header and Exhaust Installation are best performed on a lift. If a lift is not available, raise the vehicle and support on quality Jack Stands on level ground. Do not rely on ajack!

We use sealing beads on all our headers. The raised bead creates a better seal virtually eliminating leaks if installed properly. It is important to install all header bolts lightly snug and then tighten to factory torque specs starting in the center and working outward. Before starting, allow the vehicle to cool, disconnect the battery, and spray a penetrating oil on all hardware and fittings that will need to be removed. Once you remove your manifold, clean the sealing surface on the head of any old gasket debris or carbon build up.

  1. From underneath the vehicle, unbolt factory the exhaust system from the exhaust manifold collectors. Pry the exhaust system back about 1/2” to gain workspace.

  2. Remove the passenger side front tire, and inner fender panel. The inner fender panel is held in place with a combination of Phillips head screws, hex head screws, and “Christmas Tree” fasteners which “snap” off.
    Passenger Side Header

  3. Remove the starter.

  4. Place a jack, with a board between the jack and the oil pan, underneath the motor. Remove the motor mount nut (under the frame) and raise the engine approx.1”. Remove the bolts holding the motor mount plate to the engine.

  5. Remove the nuts and studs attaching the manifold to the head. Remove the manifold.

  6. Remove the gasket and any gasket material or any carbon deposits that remain on the head surface.

  7. Remove all the factory exhaust studs. There are two different threads that Ford used on these trucks. Compare your studs to the 2 sets of header bolts included in the kit and pick the proper set. Failure to do so can result in stripped heads.

  8. Slip the header over the frame from the top. It is a tight fit but will slip in.

  9. Apply anti seize to the header bolts. Slip the gasket in place, Install the supplied Header bolts and star washers. Tighten fasteners in an alternating sequence starting from the center and working out.

  10. Re-install the starter. Bolt the motor mount plate to the motor. Lower the motor and tighten lower mount bolts

Driver’s Side Header

  1. From underneath the truck, remove the nuts attaching the manifold to the head. Remove the engine oil dipstick, noting where it inserts into block. Remove the manifold.
  2. Remove the rear most top manifold stud from the head.
  3. Remove the gasket and any gasket material or any carbon deposits that remain on the head.
  4. Apply anti seize to the header bolts. Slip the gasket in place, Install the supplied Header bolts and star washers. Tighten fasteners in an alternating sequence. Reinstall the dipstick tube and dipstick.
  5. Apply a small amount of O2 sensor safe RTV silicone around the flares on the factory exhaust system then reconnect the factory catalytic convertors and exhaust system to the new headers using the supplied 2-1/2” collector bolts.
  6. Check to make sure that all the wiring, fuel lines, transmission cooler lines, brake lines, hoses, etc. are clear of the headers or any exhaust components and reroute or relocate those components as necessary.
  7. Install the inner fender panel and front wheel. Reconnect the battery.
  8. Start the engine, check for leaks and test drive. Let the engine cool and then re-torque the header bolts.
  9. Periodically check and retighten the header bolts.

JBA-1688S-Performance-Exhaust-Cat4ward-Headers-FIG

Parts List

  • (1) Driver’s Side Header Assembly: (1) Passenger’s Side Header Assembly
  • (2) Header flange gaskets: (1) CARB EO Sticker
  • (16) 10-1.5mm Header Bolts: (16) 10-1.25mm Header bolts
  • (16) 10mm Lock washers (4) 3/8-16 Nuts: (4) 3/8-16 x 2.5” Collector Bolts

JBA LIMITED WARRANTY

All JBA Headers and Exhaust products are guaranteed, to the original purchaser, to be free of defects in materials and workmanship for one year. This warranty covers the replacement or repair of the product only and does not cover the cost of removal and installation, customer applied aftermarket coatings or any discoloration or corrosion of finished surfaces.

Damage or product failure resulting from collision, improper installation, off-road use, road hazards, the use of exhaust insulating wrap or like products or rust Occurring after installation, is not covered by the warranty. The warranty extends only to the original purchaser.

Should a part become defective it should be returned to the original selling retailer and must be accompanied with the sales receipt. If there is no retailer in your area, call the factory for a return authorization and return your part prepaid to the factory for inspection. PerTronix reserves the rights to replace or repair the alleged defective part and return the part freight collect.

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