JBA 1647SJT User Manual

Corporate Ofce: PerTronix Inc. 440 E. Arrow Highway, San Dimas, California 91773 * Phone [phone] • FAX [phone]

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Installation Instructions

and Warranty Information

JBA Headers for 1998-2008

Ford Ranger with 3.0L V-6

Part# 1647S 1998-01 (with EGR)

Part #1647S-1 2002-08 (without EGR)

Read all instructions carefully before attempting installation.

rev 1 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 flanges. 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 fittings before attempting to remove them.

3. 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 work space.

4. From above loosen the air tube at the front of the driver side manifold.

5. Remove the fasteners attaching the Driver’s side manifold to the head and remove the manifold.

6. 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.

7. Remove the fasteners attaching the Passenger’s side manifold to the head and remove the manifold.

8. 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.

9. Slip the dipstick into the driver’s side header and guide it into the block as you maneuver the header
into place. On 98-01 models, Start the EGR tube before bolting the header to the head. 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 aluminum
heads.

10. 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.

11. Apply a thin coat of High Temperature, Sensor Safe Silicone on the header collector domes and re­connect the exhaust system to the headers using the hardware provided. Tighten to 35 ft./lbs.

12. 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.

13. Reconnect the battery.

14. Start the engine, check for leaks and test drive. Then let engine cool and then re-torque the header
bolts.

15. Periodically check and retighten the header bolts.

Parts List:
(1) Driver’s Side Header Assembly
(1) Passenger’s Side Header Assembly
(2) Header flange 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.