DOUG S HEADERS D626 Full Length Header Instruction Manual
- June 12, 2024
- DOUG S HEADERS
Table of Contents
A Per Trolik Performance, Brand—
www.pertronixbrands.com ∼ 909 599-5955
Installation Instructions & Warranty Information
D626 – 67-70 FORD MUSTANG & COUGAR, 390-428
NOTE: Requires Power Steering Bracket P/N H7609
NOTE: Will not fit Cobra Jet models Long Tube Headers
PERTRONIX PERFORMANCE BRANDS EMISSIONS CODES
4. This Product is considered a Replacement Part per CARE and EPA regulations
for emissions compliance and is legal for sale and use on specified vehicles
in all 50 states as stated in Manufacturer’s Application Guide and
Installation Instructions.
WARNING: 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.P6SWarnings.ca.gov
PLEASE READ BEFORE PROCEEDING
Per Tronix © thanks you for choosing a Doug’s Headers Product. To realize the
potential of Doug’s Headers 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 Per Tronix before continuing. Headers will have
the part number stamped in the flange. Many factors affect he installation of
exhaust headers, including worn or aftermarket motor mounts, previous accident
damage, aftermarket cylinder heads that may have relocated port or spark plug
locations, suspension and steering changes, sagging of original unibody
structures due to age. Coating Notes: Coatings can be marred during
installation if you are not careful. If you are breaking in a new motor, the
extreme heat can alter the appearance of the coating and this is not a
warranty issue. We recommend breaking in new motors with stock manifolds or an
old set of headers.
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. 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 a jack!
DISASSEMBLY / ASSEMBLY
LEFT SIDE:
-
Unbolt the head pipes (both sides) from exhaust manifolds and mufflers and remove.
-
Remove the power steering ram from the frame.
-
Unbolt the idler arm from the frame.
-
Remove the clutch linkage and center bolt from the motor mount.
-
Jack up the engine about 2 inches. Be sure to use a board between the pan and jack.
-
Remove both halves of the motor mount.
-
Remove the stock exhaust manifold.
-
Clean the head surface of any carbon deposits or other foreign material.
-
Apply anti-seize to the supplied header bolts.
-
Starting from below, work the header up through the chassis into position over the exhaust ports.
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With the header loose, replace the clutch linkage.
-
Start all the header bolts (most restricted first) and tighten evenly.
-
Replace both halves of the motor mounts, lower the engine and replace the center bolt in the mount.
Note: On AUTOMATIC TRANS MODELS: If the L-3 tube contacts the bellhousing between its 3rd and 4th bends, re-form for clearance (See Illustration). -
Do not reinstall the power steering ram or idler arm until the right side is installed.
RIGHT SIDE:
- Remove the stock exhaust manifold and starter.
- Remove the center bolt from the motor mount and raise the engine about 2”. Be sure to use a board between the pan and jack.
- Clean the head surface of any carbon deposits or other foreign material.
- Apply anti-seize to the supplied header bolts.
- Starting from below, work the header up through the chassis into position.
- With the header loose, reinstall the starter.
- Start all the header bolts (most restricted first) and tighten evenly.
- Lower the motor and replace the center bolt in the motor mount.
- Replace the power steering ram with the purchased H7609 Power Steering Bracket.
- Reinstall the idler arm. If the idler arm bolts contact the header tubes, either cut off the ends of the bolts or use washers (under the bolt heads) to shim the bolts further toward the outside of the frame.
- Bolt the supplied reducers to the collectors. Cut the existing head pipes to length and weld the reducers to them.
- Connect the negative battery cable.
IMPORTANT CHECK LIST
➢ Be sure that all brake lines, transmission lines, and fuel lines are clear
of headers and/or connector pipes.
➢ All spark plug wires, battery cables, or other electrical components should
be clear of headers and/or connector pipes.
➢ If dipstick tube was removed, make sure it is installed properly and that
the dipstick has been replaced.
➢ Double-check the tightness of all bolts including brackets and accessories.
START THE ENGINE
Start the engine and allow it to warm up to operating temperature. Check for
any unusual noises or exhaust leaks. If everything is OK, stop the engine and
tighten all bolts while the engine is still warm.
NOTE: Check the bolts periodically to make sure they have not loosened.
Re-tighten after the first 500 miles and then again at 1000 miles
PARTS LIST:
1 Left side header
2 Header gasket
32 Bolt, header, flanged, 3/8”-16 x 1”
6 Hex head cap screw, 3/8”-16 x 1-1/4”
1 Right side header
2 Reducer gasket
38 Lock-washer, 3/8”
6 Nut, hex, 3/8”-16
DOUG’S HEADERS LIMITED WARRANTY
All Doug’s Headers and Exhaust products are guaranteed, to the original
purchaser, to be free of defects in material and workmanship for one year from
date of purchase. This warranty covers the replacement or repair of the
product and does not cover the cost of removal and installation, customer
applied 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 rust occurring
after installation is not covered by the warranty. This warranty extends only
to the original purchaser.
Should a part be deemed defective, it should be returned to the original
selling retailer and must be accompanied by the sales receipt. If there is no
retailer in your area, contact Per Tronix direct for a return authorization
and return the part prepaid to the factory for inspection. Per Tronix reserves
the right to replace or repair the alleged defective part and return the part
freight collect.
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