PerTronix 6625S User Manual

Installation Instructions

and Warranty Information

For ’96-04 Mustang GT 4.6L and

’99-’04 Cobra 4.6L dohc V-8

Part# Description

6622S ’96-’04 Mustang GT 4.6L sohc 1-3/8” long tube
6632S ’96-’04 Mustang GT 4.6L sohc 1-5/8” long tube
6625S ’99-’04 Cobra 4.6L dohc V-8 1-3/4” long tube
6635S ’99-’04 Cobra 4.6L dohc V-8 1-5/8” long tube

Read all instructions carefully before attempting installation.

Rev. 04/06

Installation instructions for P/N 6620 Series JBA Mid-Length Headers

For ’99-’04 Ford Mustang and Cobra with 4.6L V-8

NOTE: Installation of this product requires an adequate workspace, general mechanic’s

tools, general mechanical “know-how” and a reasonable degree of experience. Most
auto enthusiasts with these resources will have little difficulty installing these headers.
However, you should carefully read these instructions before attempting to install these
headers. If in doubt, consult a professional mechanic. (Better to do it now than to get
stuck halfway through the installation.) This part is certified for use on Emission
Controlled Vehicles.

By installing your JBA Performance Exhaust product, you indicate that you have read
this document and agree with the following terms.

The Purchaser is responsible for following all installation instructions and safety
guidelines supplied with JBA Performance Exhaust products.

JBA Performance Exhaust assumes no responsibility for damages resulting from
improper operation, misuse, abuse, or lack of responsible care, or any problems
resulting from incompatibility with other manufacturer's products.

Included with your installation instructions is a copy of the product warranty. Please
read it carefully before you begin any work on your vehicle. Should you have any
questions about the warranty policy or installation, please give JBA a call at 619 229-

7797.

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 important when
installing the header, to install all bolts loosely, then tighten evenly to ensure the flat
installation of the flange. It is normal for the flange to be raised off the cylinder head the
thickness of the sealing bead.
To prevent leakage, it is important to tighten the flanges on any set of JBA headers
carefully by using the proper procedure. 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, 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. Below is the
proper torque sequence for your particular set 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. Disconnect the exhaust system from the catalytic converter assembly. Unplug O2
sensors and remove the converter assembly from the vehicle.

4. Unbolt the starter from the bell housing and let it hang out of the way.

5 Loosen the EGR tube located at the rear of the driver side manifold.

6. Remove the motor mount nut under the passenger side manifold.