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
Part # 1660 and 1660-1
1966-77 Ford Bronco
289/302/5.0 EFI
These headers were specically designed to t 66-77
Broncos with late model 5.0 fuel injected engines.
They will also t earlier 289 and 302 engines.
NOTE:
1.Will not t 3 or 4 Port Air Injector Tubes
without grinding Header Flanges
2. Will not t “P” Head
CARB EO #D-57-27
Read all instructions carefully before attempting installation.
Rev 1 3-18-13 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. 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. 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! Remove the spark plugs.
4. Apply penetrating oil on all accessible fasteners and fittings before attempting to remove them.
5. On 5.0 conversions, unbolt the dipstick tube bracket from the engine and remove the dipstick tube. Unbolt the
engine lift brackets and discard.
6. Remove the original exhaust head pipes from the exhaust manifolds.
7. Unbolt both the Driver’s and Passenger’s side exhaust manifold and remove. Remove the gaskets and any
gasket material or 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.
8. From above, slip either side 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. Repeat on the other side.
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.
8. Reinstall the spark plug and plug wires taking care not to let any wires rest against the header tubes.
9. Attach air cleaner heat stove to header tube with hose clamp provided if applicable. Attach Air Intake Support
bracket if applicable, modify as necessary to clear header tube.
10. Install the supplied reducers to the header dome collectors using a thin coat of High Temp Sensor Safe Silicone and the supplied Nuts & Bolts. Modify existing exhaust as necessary to attach to the reducers or fabricate
new exhaust.
11. 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.
12. 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.
13. Periodically check and retighten the header bolts.
Parts List:
(1) Driver’s Side Header Assembly (2) Header Gaskets
(1) Passenger’s Side Header Assembly (4) Collector Bolts
(16) 3/8” x 1” Header Bolts (4) Collector Nuts
(16) 3/8” Lock Washers (2) 2-1/2” Reducers
(2) 2-bolt anges (1) Hose clamp
(1) Heat stove
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 discoloration 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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