PerTronix D4470 User Manual

Corporate Office: PerTronix Inc. 440 E. Arrow Highway, San Dimas, California 91773 * Phone [phone] * FAX [phone] * www.dougsheaders.com

2004 ONLY

2005

HEADER INSTALLATION INSTRUCTIONS

PART NUMBER: D4470

APPLICATION

2004-05 DODGE 2500 PICK-UP 5.7L “HEMI” 4WD

PerTronix

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. Most installations require
some welding. If you are uncomfortable with welding operations, we recommend that you contact a professional exhaust
system specialist to install your new headers.

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.

©

thanks you for choosing

DOUG’S HEADERS

, the best fitting, highest quality header on the market. In order

DISASSEMBLY

1. Disconnect the negative battery cable from the battery.

2. If a car lift is not available, raise the vehicle 2 feet or higher and support it with
adequate safety stands. Make sure the vehicle is on a flat solid surface and is stable.

3. Apply penetrating oil to all nuts and bolts to be removed.

4. Remove ALL of the O2 sensors. Use care not to damage the wires when disconnecting
from the sensors. Take care not to drop the sensors.

5. Cut the passenger side connector pipe at the front of the Catalytic Converter. This cut
must be made on the Converter side of the weld that holds the converter heat shields

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on. This cut must be made as close to the weld as possible, it can even be slightly into
the weld. Refer to figure 1 for exact position of the cut.

6. Cut the driver side connector pipe at the weld in the center of the truck. This cut must
be made as close as possible to the weld and be on the down stream side of the weld.
The successful completion of this cut will leave the inlet pipe to the Catalytic Converter
without any of the weld bead present.

7. Unbolt and remove the connector pipes.

8. Remove both front wheels.

9. Remove both inner fender panels.

10. Remove the exhaust manifold heat shields.

11. Remove the stock exhaust manifolds.

12. Remove all the exhaust manifold studs from the cylinder heads

13. Clean the cylinder heads. Make sure that all residue is removed and the mounting
surface has no carbon or gasket material remaining.

ASSEMBLY

1. Match the header gaskets with the appropriate header. Make sure that the EGR port
on the header is aligned with the gasket.

2. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the header
side of the header gaskets. Stick the gasket to the appropriate header. Masking tape
can be used to help hold the gaskets to the headers.

3. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the cylinder
head side of the header gasket.

4. Install both headers utilizing header bolts (w/a small amount of anti-seize) and lock
washers supplied. Install all the bolts finger tight then tighten the bolts evenly to about
25 foot pounds of torque.

5. Install the inner fender panels.

6. Install the front wheels and torque the lug nuts to factory specification.

7. Install the driver side connector pipe onto the Catalytic Converter inlet pipe. Attach the
connector pipe to the header utilizing the metal doughnut gasket and fasteners supplied
with the headers. Do not tighten at this time.

8. The passenger side connector pipe needs to slide into the converter. If it doesn’t, file or
grind clearance on the converter inlet to allow the pipe to fit.

9. Slide the passenger side connector pipe into the Catalytic Converter.

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10. Attach the connector pipe to the header utilizing the metal doughnut gasket and
fasteners supplied with the headers. Do not tighten at this time.

11. Adjust connector pipes for best alignment and tighten the pipes to the headers evenly.

12. Weld the driver side connector pipe to the front of the Catalytic Converter and the driver
side connector where it slips over the Catalytic Converter inlet pipe. If you do not have
a welder available, skip this step and complete the installation. After you complete the
installation you can drive the truck to a muffler shop to complete this operation.

13. Apply anti-seize to all the O2 sensors threads and install in their appropriate locations.

14. Plug the wires into the O2 sensors making sure that they are routed away from hot
pipes. (We recommend that O2 sensors be removed before any welding operation is
done on the exhaust system.)

15. Connect the negative cable to the battery.

START THE ENGINE

Start the engine and allow it to warm up to operating temperature. Check for any unusual noises or exhaust leaks.
If every thing is OK, stop the engine and tighten all bolts while the engine is still warm.
NOTE: Check the bolts periodically to make sure they have not loosened. Re-tighten after the first 500 miles and
then again at 1000 miles.

IMPORTANT CHECK LIST

Be sure that all brake lines and fuel lines are clear of headers and/or connector pipes.
All spark plug wires, battery cables, or other electrical components should be clear of headers

and/or connector pipes.

If dipstick tube was removed, make sure it is installed properly and that the dipstick has been

replaced.

Double-check the tightness of all bolts including brackets and accessories.

PARTS LIST

Qty. Description

1 Right side header
1 Left side header
1 Right side connector pipe
1 Left side connector pipe
1 Left side header gasket
1 Right side header gasket
2 2 ½” metal donut gaskets
1 Sticker, C.A.R.B., E.O., D-57-19
1 Hardware kit:
17 8mm lock-washers
6 3/8”-16 x 2 ¼” hex bolts
6 3/8”-16 hex nuts
6 3/8” lock-washers
17 8mm x 1.25 x 30mm hex flanged bolts

1 Decal:

DOUG’S HEADERS

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