Corporate Ofce: PerTronix Inc. 440 E. Arrow Highway, San Dimas, California 91773 * Phone 909.599.5955 • FAX 909.599.6424
Installation Instructions
and Warranty Information
Part #1627S 1987-95 F-150/Bronco 5.0 L
Part #1627S-1 1996 F-150/Bronco 5.0L
Part #1628S 1986-96 F-150/F-250/Bronco 5.8L
Part #1628S-2 1993-95 5.8L Lightning
Part #1628S-3 1987-96 F-250 5.8L w/Port Air Inj.
Part #1628S-4 1987-96 F-250 5.8L w/Dual Air Inj.
CARB EO # D-57-27
Read all instructions carefully before attempting installation.
Rev. 3 2-28-13 DSL
PerTronix© thanks you for choosing JBA 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.
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.
JBA uses sealing beads on all its headers. We have found that when installed correctly, the raised bead around each port
increases the pressure exerted on the gasket directly adjacent to the port and effectively prevents leaking gaskets. It is
normal for the flange to be raised off the cylinder head the thickness of the sealing bead. It is important when installing
the header, to install all bolts loosely, then tighten evenly to ensure the flat installation of the flange. The torque sequence
from one flange to another will vary, but generally every bolt on a header should be first fit snug, starting from the inside
of the flange working out, alternating from top to bottom so that the bolt connects the flange to the manifold to the point
where they barely touch. Second, using the same inside-out pattern, tighten each bolt until nished. This method will
help prevent leakage and will give the user the best possible performance out of their pair of headers.
1. Place vehicle in a location where the floor is solid and flat, with adequate lighting. Do not attempt to work on a hot engine. Heat causes metal to expand and makes removal of fasteners difficult. Disconnect the battery cables from the battery.
Raise the front of the vehicle to obtain adequate access to the bottom exhaust manifold anges. Use large-base jack stands
to support the vehicle. Do not rely on the jack! Block the tires to prevent the vehicle from rolling off the jack stands.
2. Disconnect the spark plug wires by grasping and gently twisting the spark plug wire boots. Do not pull on the wires!
Brush or blow any debris, which may have collected around the manifolds or spark plugs. This will help prevent foreign
matter from entering the combustion chamber when the manifolds are removed. Remove the Negative Battery cable from
the battery.
3. Apply penetrating oil on all accessible fasteners and fittings before attempting to remove them.
4. Unbolt the Y-Pipe assembly from the collector anges of the factory headers.
5. Unbolt the dipstick tube bracket from the engine. Carefully slide the dipstick tube upward to remove.
6. Unbolt the Driver’s side exhaust manifold and remove. Remove the gaskets and any gasket material or any carbon deposits that remain on the head surface. The use of a gasket removal agent will ease the removal of any gasket material. Use
care not to get debris into ports or spark plug holes. Clean excess carbon deposits from the Y-Pipe mating ange.
7. Apply anti-seize to the header bolts if installing on aluminum heads. Bolt the Driver’s side header to the head using the
supplied header gasket, header bolts, and lock washers. Torque to 30 lbs./ft on iron heads, 16 lbs./ft on alum.
8. Modication of the Dip Stick Tube Bracket is required on some vehicles. Grind the bracket to allow it to t between the
header tube and the header bolt (See Illustration). On some models the use of a spacer along with a stock manifold stud allow the dipstick to be re-attached with no modication. Clean all grease/oil from the
outside of the dipstick tube. When ready to re-install the dipstick tube, apply a small
amount of silicone sealant to the outside of the dipstick tube where it slip-ts into the
engine.
9. Unbolt the passenger side manifold and EFI plenum support.
a. On 1986 & 1996 5.0: remove the O2 sensor from the tting on the rear of the manifold.
b. On 1986-96 5.8 w/o air injection: remove the EGR tting from the front
of the passenger side exhaust manifold.
Install the passenger side header temporarily with a couple of bolts (no
gasket) to facilitate the test fitting of the surrounding components as
discussed below. Note that the bottom portion of the plenum support
bracket will have to be ground to clear the new larger header tubes. (The
modification is similar to the dipstick tube bracket modification.) The
bottom end of the plenum support must also be bent slightly since it is
now attached at a point closer to the engine. [See diagram.]
10. The tube running past the headers is the catalytic converter’s secondary air injection tube. On 1986 & 1996 5.0 the
tube has one bracket, which bolts to the head via the factory exhaust manifold bolt. On 1987-95 5.0, the tube has two
brackets.
11. Secondary air Injection Tube Modications;
a. 1986-96 5.8 w/o air injection: The secondary air injection tube has a plastic diverter valve towards the rear. This valve
must be kept away from the headers. To do this, the tube must be moved outward by using the
steel extension bracket (included) to allow the air injection tube to stand off from the headers. The
bracket bolts to the head where the secondary air injection tube originally was attached. The secondary air injection tube is then bolted to the adapter bracket.
b. 1986-95 5.0: The secondary air injection tube can be re-attached in the factory location. As with
the dipstick tube, the use of a spacer and a stock stud allows the secondary air injection tube to be re-attached in the fac-
tory location.
12. After the above modifications have been performed, remove the temporarily installed header. Remove the gaskets and
any gasket material or any carbon deposits that remain on the head surface. The use of a gasket removal agent will ease
the removal of any gasket material. Use care not to get debris into ports or spark plug holes. Clean excess carbon deposits
from the Y-Pipe mating ange. Apply anti-seize to the header bolts if installing on aluminum heads. Bolt the header to
the head using the supplied header gasket, header bolts, and lock washers. Torque to 30 lbs./ft on iron heads, 16 lbs./ft on
alum. At the same time reinstall the secondary air injection tube as discussed above in 9a or 9b.
On 1986 & 1996 5.0: reinstall the O2 sensor on the tting on the rear of the collector.
On 1986-96 5.8 w/o air injection: reinstall the EGR tting into the tting welded to the front tube of the header.
13. Apply a thin coating of High Temperature, Oxygen Sensor Safe, Silicone Sealant to the collector dome on each header.
Attach the headers to the Y-Pipe from the underside using the supplied nuts and bolts.
14. Reinstall the spark plug wires and looms taking care not to let any wires rest against the header tubes. Reinstall the
negative battery cable.
15. Check that all bolts are tight. Make sure that all wiring, fuel lines, transmissions lines, brake lines etc are clear
of the headers and the exhaust and relocate as necessary.
16. Start the engine and let it warm up. Check for leaks. Shut engine off and let it cool down. Check to make sure all fas-
teners are tight. Periodically check and retighten the header bolts.
Parts List:
(1) Driver’s Side Header Assembly
(1) Passenger’s Side Header Assembly
(16) 3/8” x 1” header bolts &lock washers
(2) Header gaskets (Header to Head ange)
(4) Collector Bolts &Nuts.
(1) Secondary Air Injection Tube Adapter Bracket &Fastener. [1628 models only.]
(2) Dipstick/Air injection tube spacers
LIMITED ONE YEAR 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 discolor-
ation or corrosion of nished 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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