Edelbrock 65633, 65632 user manual
Edelbrock Headers
For 1999-2003 Ford F-150, 1999-2002Expedition,
1999-2002 Ford F-250 Excluding Super Duty,
5.4L V8 2WD &4WD without Air Ride Suspension
Catalog #65632 & #65633
INSTALLATION INSTRUCTIONS
Please study these instructions carefully before installing your new Headers. If you have any questions or problems, please contact
our Technical Hotline at : 1-800-416-8628 from 7 am – 5 pm, Monday through Friday, Pacific Standard Time or e-mail us at
edelbrock@edelbrock.com. Please complete and mail your warranty card.
DESCRIPTION: These components are designed to improve the exhaust efficiency of the Ford 5.4 Litre V8 engine. This system does
not require welding for installation and retains all O.E.M. emissions equipment. These Edelbrock headers are street legal in all 50
states. These systems should be installed by an experienced/qualified mechanic.
Suggested tools needed for installation: This vehicle has some metric fasteners.
❑ 3/8" ratchet socket set with extensions and universal 13mm and 15mm swivel sockets
❑ Combination set of open-end wrenches
❑ Jackstands, screwdrivers, pliers, crescent wrench, etc.
❑ Liquid penetrant, (GM #1052627) anti-seize compound (GM #5613695)
❑ 13mm open end wrench (stubby)
❑ 1/4" ratchet socket set with extensions and swivel
SPECIAL NOTICE: This Edelbrock part has received an Executive Order number (E.O. #) from the California Air Resources Board
(C.A.R.B.) making it legal for street use on pollution-controlled motor vehicles in all 50 states. To assist you with emissions equipment
certification, we have included a silver fan shroud decal to help testing personnel verify that this part is a legal replacement part on
the vehicle for which it is cataloged. The adhesive-backed decal should be affixed to your fan shroud next to the existing emission
and engine specification decal. Do not cover your original equipment specification decal with the Edelbrock fan shroud decal.
WARNING: The use of “Thermal Wrap” or any aftermarket coating process will void the warranty on your Headers. Those products
can cause excessive heat and moisture build up resulting in corrosion and early failure of the system.
INSTALLATION INSTRUCTIONS
DISASSEMBLY:
1. Disconnect negative battery cable.
2. Raise truck and disconnect exhaust pipes from both
left and right manifolds.
3. Removal of front tires will make installation much
easier.
4. Remove both left and right plastic fender wells.
5. Disconnect and remove starter from vehicle.
LEFT SIDE
1. Disconnect and remove EGR tube from vehicle.
2. Remove nuts and studs from manifold.
3. Remove stock manifold and gasket from vehicle
through wheel well.
4. Disconnect dipstick. (Note: Dipstick must be placed
between primary pipes 2 & 3 before bolting on
header).
5. Install port flange gasket and one 8mm bolt, lock
washer, and flat washer at rear most bolt hole. Leave
bolt loose enough to accept header.
6. Place header into position through wheel well. With
dipstick and header in place, start all bolts and
washers, then tighten evenly from center out.
7. Install the new EGR tube (supplied with system).
©2005 Edelbrock Corporation
Catalog #65632 & #65633
Page 1 of 2
Brochure #63-0401
Rev. 5/05 - DA/mc
RIGHT SIDE
1. Remove bracket from air conditioning lines that
mounts to firewall to allow air lines to move around
freely (Ford Expedition Only).
2. Remove nuts and studs, then remove stock manifold
and gasket from vehicle through wheel well.
3. Install port flange gasket and one 8mm bolt, lock
washer, and flat washer at rear most bolt hole.
Leave bolt loose enough to accept header.
4. Place header into position through wheel well. Start
all bolts and washers, then tighten.
5. Reconnect air conditioning lines to firewall.
FINAL ASSEMBLY
1. Bolt on and re-connect starter to vehicle.
2. With collector donuts on headers, re-connect exhaust
pipes to headers using supplied bolts and lock
washers.
3. Re-connect battery.
4. Start vehicle and bring up to normal temperature.
Check for possible leaks.
5. Turn engine off and let cool. Re-tighten all bolts.
6. Re-install fender wells.
7. Re-install front tires if removed. Be sure to torque
lug nuts to factory specifications.
Part #65632 (Ceramic-Coated) - Parts List
Qty. Part # Description Qty. Part # Description
1 25-9257 Manifold left side 16 - 8mm x 1.25” x 30mm Header bolts
1 25-9258 Manifold right side 16 - 5/16” Lock washers
1 25-9666 EGR tube assembly 16 - 5/16” I.D x 1/8” thick Black
2 - Port gaskets hardened washers
2 - Donut gaskets - 2 1/2” diameter 4 - 3/8” - 16 x 2” Hex bolts
4 - 3/8” Lock washers
Part #65633 (Ti-Tech Coated) - Parts List
Qty. Part # Description Qty. Part # Description
1 25-9237 Manifold left side 16 - 8mm x 1.25” x 30mm Header bolts
1 25-9238 Manifold right side 16 - 5/16” Lock washers
1 25-9666 EGR tube assembly 16 - 5/16” I.D x 1/8” thick Black
2 - Port gaskets hardened washers
2 - Donut gaskets - 2 1/2” diameter 4 - 3/8” - 16 x 2” Hex bolts
4 - 3/8” Lock washers
Edelbrock Corporation
2700 California Street
Torrance, CA 90503
Toll-Free Tech Line: 1-800-416-8628
Tech E-Mail: edelbrock@edelbrock.com
©2005 Edelbrock Corporation
Catalog #65632 & #65633
Page 2 of 2
Brochure #63-0401
Rev. 5/05 - DA/mc
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