PerTronix 1625S-6 1998, 1625S-8 96-98, 1625S-7 99-04, 1625S-5 96-97, 1625S-9 99-04 Installation Instructions And Warranty
Corporate Oce: PerTronix Inc. 440 E. Arrow Highway, San Dimas, California 91773 * Phone 909.599.5955 • FAX 909.599.6424
Installation Instructions
and Warranty Information
1625S-5 96-97 SVT Cobra 4.6L 4V
1625S-6 1998 SVT Cobra 4.6L 4V
1625S-7 99-04 SVT Cobra 4.6L 4V
1625S-8 96-98 Mustang 4.6L 2V
1625S-9 99-04 Mustang 4.6L 2V
Read all instructions carefully before attempting installation.
Rev.4 5-22-17 DSL
PerTronix© thanks you for choosing JBA HEADERS, the best tting, highest quality header on the market. In order to realize the full potential of our good t, 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 ange. 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 aect the installation of headers, some of which are broken or aftermarket motor mounts,
accidents that impact the conguration of the frame, and/or the installation of dierent 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 eectively prevents leaking gaskets. It is normal for the ange to be raised o 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 at installation
of the ange. The torque sequence from one ange to another will vary, but generally every bolt on a header
should be rst t snug, starting from the inside of the ange working out, alternating from top to bottom so
that the bolt connects the ange 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.
1. Place vehicle in a location where the oor is solid and at, with adequate lighting. Do not attempt to work
on a hot engine. Heat causes metal to expand and makes removal of fasteners dicult 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 o the jack stands.
2. Disconnect the Negative Battery Cable from the battery.
3. Apply penetrating oil on all accessible fasteners and ttings before attempting to remove them.
4. Unplug the Oxygen Sensors from the exhaust system. Disconnect the exhaust system from the catalytic
converter assembly. Remove the converter assembly from the vehicle.
5. Remove the Starter Motor.
6. Remove the motor mount nut under the passenger side manifold.
7. Place a block of wood between the oil pan and a jack. Remove the passenger side motor mount bolts and lift the
motor approx. 1”
8. With engine jacked up, remove the passenger side manifold and remove the manifold studs. Note: On 96-97 Cobra
installations you will need to disconnect the air tting from the front of the manifold.
9. Due to the limited space in the engine compartment you will need to relocate the air conditioning line that run by
the passenger side manifold. This is done by bending the soft aluminum line up slightly and reattaching it using the
factory bracket into the alternate hole located approximately 2 ”above the factory’s original mounting hole. See the
illustration below.
10. Apply a small amount of anti-seize to all header bolts. Install the passenger side header using the supplied hard-
ware and gasket. Torque to 13 lbs./inch. Reconnect the air tting on 96-7 Cobra’s.
11. Lower the engine onto the motor mount and tighten the motor mount nut.
12. Reinstall the starter.
13. Disconnect the steering shaft from the steering rack and swing it out of the way. Remove the Oil Filter
14. Disconnect the EGR tube from the driver side manifold and remove the driver side manifold and dipstick tube.
Note: On 96-97 Cobra installations you will need to disconnect the air tting from the front of the manifold. Remove all
of the manifold studs.
15. From underneath the vehicle, slip the new header into place. From the top, slide the dipstick tube through the
header between the second and third tube. Guide the tube under the motor mount and into its hole.
16. Loosely attach the EGR tube to the new header. Apply a small amount of anti-seize to all header bolts. Install the
driver’s side header using the supplied hardware and gasket. Torque to 13 lbs./inch. Reconnect the air tting on 96-7
Cobra’s.
17. Tighten the EGR tube. Reconnect the steering shaft to the steering rack. Attach the dipstick tube to the head using
the supplied spacer and original bolt. Reinstall the oil lter.)
18. Re-install the H-pipe using the supplied collector gasket on the passenger side. Apply a small bead high tempera-
ture, sensor safe silicone around the dome on the driver’s side header for added leak protection, and then reconnect
the exhaust system.
19. Reconnect the battery cable.
20. 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.
21. Start the engine and let it warm up. Check for leaks. Shut engine o and let it cool down. Check to make sure all
fasteners are tight.
22. Periodically check and retighten the header bolts.
Parts List:
(1) Driver’s Side Header Assembly (18) 8mm x 1.25 Header bolts
(1) Passenger’s Side Header Assembly (18) 8mm Lock Washers
(2) Header gaskets (Header to Head ange) (2) 3/8 ”x 1-1/2 ”Collector bolts
(1) Base ange gasket (2) 3/8 ”x /2 ”Collector bolts
(4) 3/8” Flat Washers (2) 3/8” Lock Washers
(2) 8mm at washers (1) 8mm x 1.25 nut
(1) Dipstick tube spacer (1) Carb Sticker
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, o-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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