JBA 1678SJT User Manual

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

Installation Instructions

and Warranty Information

Part # 1678S 2002-05 Ford Explorer 4.6L V-8

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 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. Then unbolt and remove the front wheels.

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

3. From underneath the vehicle, unbolt factory the exhaust system from the exhaust manifold collectors. Pry the

exhaust system back about 1/2” to gain workspace.

4. It is easier to gain access to manifolds if you remove front tires, and inner fender panels. The inner fender
panels are held in place with a combination of Phillips head screws, hex head screws, and “Christmas Tree”
fasteners.

Driver’s Side Header

5. Remove the three screws attaching the heat shield to the manifold. Now remove the heat shield.

6. Remove the nuts and studs attaching the manifold to the head. Remove the dipstick noting where it inserts

into block. Remove the manifold. (On some models it may be necessary to separate the steering shaft at the slip
joint near the firewall)

7. Clean the head surface of any carbon deposits with a scraper or wire brush (be careful not to gouge the head
surface).

8. Slip the header and dipstick into position. Install the header using the fasteners, lock washers and gaskets
provided.

9. Apply a small amount of anti-seize to the new headers bolts. Install the headers using the supplied bolts,
washers, and gaskets. Torque to 13 ft/lbs.

Passenger Side Header

10. Remove the three screws attaching the heat shield to the manifold. Remove the heat shield.

11. Disconnect the EGR tube from the rear of the manifold.

12. It will be necessary to removed the motor mount nut (under the frame) and raise the engine approx.. 1”.
Remove the nuts and studs attaching the manifold to the head. Remove the manifold.

13. Clean the head surface of any carbon deposits with a scraper or wire brush (be careful not to gouge the head
surface).

14. Slip the header into place, and loosely attach the EGR tube to the header. Replace motor mount nut. Tighten
the EGR tube.

15. Apply a small amount of anti-seize to the new headers bolts. Install the headers using the supplied bolts,
washers, and gaskets. Torque to 13 ft/lbs. Apply a small amount of Hi-temp RTV (sensor safe) to the exhaust
pipe flare and re attach the exhaust pipes to the headers.

16. Check to ensure that there is adequate clearance on all brake lines, wire looms, A/C lines, etc.

17. Install the inner fender panels and front wheels.

18. Reconnect the battery.

19. Re-check everything!

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

21. 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

(16) 8mm-1.25 x 25mm Header fasteners w/lock washers
(4) 7/16 -14 x 2.5 ”Collector bolts w/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.