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
1994-1995 5.0L Mustang/Cobra
Part # 1624S-4
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.
INSTALLATION INSTRUCTIONS:
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. Raise the front of
the vehicle to obtain adequate access to the bottom exhaust manifold anges. Use large-base jack stands to sup-
port the vehicle. Do not rely on the jack! Block the tires to prevent the vehicle from rolling off the jack stands.
2.Disconnect the negative battery cable from the battery.
3. 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.
4.Apply penetrating oil on all accessible fasteners and fittings before attempting to remove them.
5. Unbolt the H-Pipe assembly from the collector anges of the factory headers. Insure that no pressure is
placed on the O2 sensor wires, disconnect if necessary. The H-Pipe does not need to be removed.
6. Unbolt the dipstick tube bracket from the engine and remove the dipstick tube. Unbolt the engine lift brackets
and discard.
7. 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 H-Pipe mating ange.
8. From above, slip the header into position. Slide the gasket into place and install the supplied header bolts and
lock washers. Anti seize is recommended on aluminium heads. Torque the bolts to 25 ft. lbs. on iron heads, 23
ft.lbs. on Aluminum heads starting from the center and working out.
9. It may be necessary to grind the Oil Dipstick tube mounting tab to clear the header tube. See Illustration
below. Once it is clearanced, insure that it is clean, apply a small amount of sensor safe silicone around the end
of the tube where it slip into the block and reinstall the tube.
10. Remove the passenger side EGR tube from the stock manifold. Unbolt the passenger side 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 H-Pipe mating ange.
11. From above, slip the header into position. Slide the gasket in to place and install the supplied header bolts
and lock washers. Anti seize is recommended on aluminium heads. Torque the bolts to 25 ft. lbs. on iron heads,
23 ft.lbs. on Aluminum heads starting from the center and working out. Use the 3/8” X 2” bolt with the spacer
in the rear most header bolt hole. The EGR Tube tab will bolt to this bolt to space the tube out from it’s original
location.
12. Apply a light coating of Sensor Safe Hi Temp Silicone to the collector dome on both headers. Install the sup
plied collector bolts into the collector flange holes from the topside. Have an assistant hold a wrench on the bolt
head from the topside when putting the nuts on and tightening from the bottom side. The procedure is the same
for both sides.
13. Reinstall the spark plug wires and looms taking care not to let any wires rest against the header tubes.
14. 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 fasteners are tight
17. Periodically check and retighten the header bolts.
Parts List:
(1) Driver’s Side Header Assembly
(1) Passenger’s Side Header Assembly
(15) 3/8 ”x 1 ” Header Bolts & Lock Washers
(1) 3/8 ”x 2 ” Header Bolt & Lock Washer
(1) 1 ” Tubular Spacer
(2) Header Gaskets (Header to Cylinder Head)
(4) Collector Bolts &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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