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
1998-2000 Ford Ranger with 4.0L OHV V6
Part #1634S-2 W/O EGR
Part # 1634S-3 W/EGR
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
finished. 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 at best. 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. Apply penetrating oil on all accessible fasteners and ttings before attempting to remove them.
3. Disconnect the negative battery cable from the battery.
4. From underneath the vehicle, loosen the bolts connecting the exhaust system to the exhaust manifolds. Move
the exhaust system back about 1/2” to gain workspace.
5. If equipped remove the EGR tube from the EGR valve and the exhaust manifold.
6. On the driver’s side, remove the fasteners attaching the manifold to the head and remove the manifold.
7. The dipstick must now be removed. It has a separate mounting bolt on the head and uses an O-ring seal at the
bottom. Use care to protect the O-ring.
8. On the passenger side, remove the fasteners attaching the manifold to the head then remove the manifold.
9. Unbolt the bracket and cable from the passenger side, above the exhaust manifold. Retain the larger bolt for
reuse.
10. 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 Exhaust system mating flange.
11. Slip the dipstick into the driver’s side header and guide it into the block as you maneuver the header into
place. Apply anti-seize to the header bolts if installing on aluminum heads. Bolt the Driver’s side header to the
engine using the supplied gaskets, bolts, and lock washers. Torque to 30 lbs./in on iron heads 23 lbs./in on alu-
minum heads.
12. Install the passenger side header through the wheel well. Apply anti-seize to the header bolts if installing
on aluminum heads. Bolt the header to the engine using the supplied gaskets, bolts, and lock washers. Torque to
30 lbs./in on iron heads, 23 lbs./in on aluminum heads.
13. Put a thin coat of High Temperature, Silicone Safe, Silicone on the header collector domes and re-connect
the exhaust system to the headers using the hardware provided. Tighten to 35 ft./lbs.
14. Models with EGR ttings only. Remove the EGR adapter tting which adapts the EGR tube to the t-
ting on the factory manifold. This adapter must be reused. Thread the adapter into the fitting on the header and
reconnect the EGR tube. (Note: Some Models may or may not have this adapter)
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. Reconnect the battery.
17. Start the engine, check for leaks and test drive. Then let engine cool and then re-torque the header bolts.
18. Periodically check and retighten the header bolts.
Parts List:
(1) Driver’s Side Header Assembly
(1) Passenger’s Side Header Assembly
(2) Header ange gaskets
(13) 8mm - 1.25 x 25mm Header bolts
(13) 8mm lock washers
(4) 3/8 - 16 x 2” Collector bolts
(4) 3/8” Nuts
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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