JBA 1669SJT User Manual

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

Installation Instructions

and Warranty Information

1999-2004 Ford Super-Duty Truck, Excursion, Motor Home

Part #1669S Triton 6.8L V-10 Engine W/O EGR

Part #1669S-1 Triton 6.8L V-10 Engine W/ EGR

CARB EO # D-57-25

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. Sec-

ond, 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 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. Spray WD-40 or some type of penetrating oil on all accessible fasteners and fittings before attempting
to remove them.

3. Start by removing the factory y-pipe. Unbolt the y-pipe from the rest of the exhaust system and the
stock manifolds and disconnect the O2 sensors.

4. Next, If equipped, loosen the EGR tube from the driver side manifold.

5. Remove the nuts attaching the manifolds to the heads. Remove the manifolds. Remove the studs from
the heads.

6. Remove the dipstick by unbolting the factory bracket.

7. Using a scraper remove all carbon deposits and high spots from head surface, use care not to gouge
the aluminum heads.

8. From underneath the vehicle, slip the new headers into place. Apply a small amount of anti-seize to
the threads of the supplied bolts.
Passenger Side: Slide the header into place and install using the supplied gasket, Header Bolrs and
Washers. Torque to 23 ft/lbs.
Driver Side: Slide the dipstick through the header into its hole. Make sure it is seated well. Loosely
attach the EGR tube. Using the supplied gasket, headers bolts and washers install the header and
torque to 23 ft./lbs. Now tighten the EGR tube and dipstick bracket.

9. Apply a small amount of Hi-temp RTV (sensor safe) around the exhaust pipe flares. Reinstall the factory
y-pipe using the supplied hardware. Then reconnect the O2 sensors.

10. Recheck everything. Make sure there is adequate clearance on all lines (vacuum, brake, A/C, fuel)

11. Reconnect the battery cables.

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

13 Periodically check and retighten the header bolts.

Parts List:

(1) Driver Side Header Assembly
(1) Passenger Side Header Assembly
(2) Header gaskets
(4) Collector Bolts & Nuts.
(20) 8mm x 25mm Bolt w/ lock washers

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.