Corporate Office: PerTronix Inc. 440 E. Arrow Highway, San Dimas, California 91773 * Phone 909.599.5955 * FAX 909.599.6424 * www.dougsheaders.com
2004 ONLY
2005-08
HEADER INSTALLATION INSTRUCTIONS
PART NUMBER: D4476
APPLICATION
2004-08 DODGE DURANGO 5.7L “HEMI”
PerTronix
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 to
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 any of the sensors.
5. Cut the 2 connector pipes at the front of the Catalytic Converters. These cuts must be
made on the Converter side of the welds that holds the converter heat shields on. These
cuts must be made as close to the weld as possible, they can even be slightly into the
weld. Refer to figure 1 for exact position of the cuts.
Part No. 0110-003031 Page 1 of 3 REV.2 3-5-13 DSL
6. Unbolt and remove the connector pipes.
7. Remove both front wheels.
8. Remove any wire harness or component that is attached to the inner fender panels.
9. Remove both inner fender panels. They are held in by 6 plastic rivets and 2 plastic panel
retainers on each side. Use an 1/8” drill bit and drill out the plug in the center of each rivet
and then remove them from the fender panel. Pry out the plastic panel retainers.
10. On 4 WD models remove the front drive shaft.
11. Remove the lower steering shaft bolt; lift the steering shaft up to remove it from the
steering box. Move the lower steering shaft on top of the frame to allow clearance for
removal of the stock manifold and installation of the header.
12. On the driver’s side, unclip the shift cable from the mounting clip on the bell housing.
Remove the clip from the bell housing and move it to the empty bottom hole on the bell
housing. Replace and tighten the bolt where the clip was originally and mount the clip in
the lower hole utilizing the supplied 3/8” x 1 ¼” bolt, lock-washer, and nut. Do not put the
shift cable back into the clip at this time.
13. Remove the exhaust manifold heat shields.
14. Remove the stock exhaust manifolds.
15. Remove all the exhaust manifold studs from the cylinder heads
16. 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 (with 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 steering shaft back onto steering box, install the lock bolt and tighten.
6. Install the shift cable into its clip on the bell housing.
7. On 4 WD vehicles, install the front drive shaft.
8. Install the inner fender panels using 16 new plastic push in *Panel Retainers
(Dorman®, Part No. 799-135 or their equivalent). These are available
at most auto parts supply stores.
9. Reattach any wires and/or components that were attached to the inner fender panels.
Part No. 0110-003031 Page 2 of 3 REV.2 3-5-13 DSL
10. Install the front wheels and torque the lug nuts to factory specification.
Applicable to 2004 ONLY!
11. Install the connector pipes into the Catalytic Converters.
12. Attach the connector pipes to the headers utilizing the metal doughnut gaskets and
fasteners supplied with the headers.
13. Adjust for best alignment of both joints and tighten evenly.
14. Weld the connector pipes to the front of the Catalytic Converters.
15. If you do not have a welder available, complete the installation without welding. (When
installation is complete, drive the vehicle to a muffler shop to complete the operation).
16. Apply anti-seize to all the O2 sensors and install in their appropriate locations.
17. 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.)
18. Lower the vehicle to the ground.
19. Connect the battery cable.
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 was replaced.
Double-check the tightness of all bolts including brackets and accessories.
PARTS LIST
Qty. Description
2 Headers (1 Right side header and 1 Left side header)
2 Connector pipes
1 Left side header gasket
1 Right side header gasket
2 2 ½” Metal donut gaskets
1 Decal:
1 Sticker, C.A.R.B., E.O., D-57-19
1 Hardware kit:
17 8mm x 1.25 x 30mm hex flanged bolts
17 8mm lock-washers
6 3/8”-16 x 2 ¼” hex bolts
1 3/8”-16 x 1 ¼” hex bolt
7 3/8”-16 hex nuts
7 3/8” lock-washers
*Additional customer supplied parts:
Qty Description
16 Plastic Panel Retainers (Dorman®, Part No. 799-135 or their equivalent)
DOUG’S HEADERS
Part No. 0110-003031 Page 3 of 3 REV.2 3-5-13 DSL
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