PerTronix 6690S User Manual

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

Installation Instructions

and Warranty Information

6690S 2005-2006 Ford GT

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. These headers are best installed on a drive on lift.

2. Remove trunk liner. Disconnect Neg. Battery cable.

3. Remove the rear section, and next section forward of the belly pan.

4. Remove the rear hatch. This is a three-person job. Disconnect the electrical
connector, pull the two little hairpins from the pivot pins, two people hold the
hatch while the third disconnects the lift struts, and pulls the pivot pins. To
separate the hinges the hatch must be lowered slightly, and slid forward and up.

5. The rear lower grille must be removed.

6. Remove the air box.

7. To remove the muffler- Remove the six nuts attaching the cat assemblies to the
muffler. Remove the four bolts attaching the cross bracket to the muffler.
Remove the three nuts attaching the cross bracket to the vertical bracket on the
rear of the transaxle. Remove the vertical bracket, and the cross bracket.
Support the transaxle from below. Remove the through-bolt at the top of the
trans-axle to the frame. Lower the trans axle until it stops. Move the shift arm
forward. The muffler can now be removed. It weighs more than 50 lbs, and is
awkward, so an extra person is highly recommended.

8. Unplug the O2 sensors. Remove nuts attaching Cat assemblies to the manifolds.

Remove Cat assy’s rearward, and up through the top.

9. Remove the bolts attaching the heat shields to the exhaust manifolds. Remove
heat shields.

10. Remove the EGR tube.

11. Remove the nuts and studs attaching the manifolds to the heads. Remove the
manifolds from the vehicle.
Installing the headers.

12. Remove the nuts and bolts attaching the axle heat shields to the trans axle.

Remove the shields.

13. Remove the six Torx head bolts attaching the CV joints to the trans axle.
Collapse the half shaft slightly to allow the CV joint to clear the companion
flange, and raise the half shaft above the flange.

14. From the rear underside, slip the headers into place, under the half shafts, all the

way forward.

15. Using the gaskets and hardware provided, bolt the headers to the motor.
Replace through bolt on trans axle. Re-connect half shafts, and heat shields.

16. Check to insure adequate clearance on the clutch hydraulic line. If necessary it

can be slipped out of it’s bracket and lowered slightly.

17. Re-install EGR tube.

18. Install the new exhaust pipes using the supplied V-band clamp. * Note- The bolt

and nut provided with the clamp are stainless, and will gall. Use anti-seize on

bolt. Swap O2 sensors to Cat pipes.

19. If re-installing factory muffler reverse disassembly procedure. If installing JBA
(Item name) use hardware supplied, and reverse disassembly procedure.

20. When the exhaust system is buttoned up, check to insure adequate clearance on

clutch line, Starter wires, etc.

21. Re-connect battery cable.

22. Start engine and check for leaks.

23. Re-install hatch, grill, and belly pan pieces.

Parts List:
(1) Driver’s Side Header
(1) Passenger Side Header

(2) Header Gaskets

(1) Bolt Kit

(2) 3” Breaker Clamp

Other recommended parts:

40-2636 – 2005-2006 Ford GT Mufer System
6690D – 2005-2006 Ford GT Downtubes
6690DC – 2005-2006 Ford GT Downtubes with

Catalytic Converters

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.