PerTronix D624 User Manual

Corporate Office: PerTronix Inc. 440 E. Arrow Highway, San Dimas, California 91773 * Phone 909.599.595 5 * FAX [phone] * www.dougsheaders.com

HEADER INSTALLATION INSTRUCTIONS

PART NUMBER: D624

Original Shelby Cobra 260-289

Replica Cobra’s with 260-302 Ford and factory style frame

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.
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.

IMPORTANT – Please Read. These headers were designed on an original 289 Cobra,
chassis #CSX2291. As is well known, these cars can vary from one to the next and we
have tried to account for this as much as possible and still fit a large long tube header in
the chassis. Due to the nature of these cars, it is possible that some slight modification
of the tubes could be necessary

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 with adequate
safety stands. Make sure the vehicle is on a flat solid surface and is stable.

3. Remove spark plug wires and spark plugs.

4. Remove the existing headers or manifolds

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5. Remove the gaskets and any gasket material or any carbon deposits that remain on the

head surface. The use of a gasket removal agent will ease the removal of any gasket
material.

INSTALLATION

1. Starting on the passenger side, slide the header into place from UNDER the car. It
should slip into place without any clearance issues, but again with these cars there can
be variances.

2. Using the supplied Doug’s Premium gaskets, bolt the header to the cylinder head using
the special header bolts and star washers. Snug each bolt before torqueing to 25 ft. lbs.
starting from the center and working outwards.

3. On the driver’s side things get tight. The driver’s side header features a slip tube on the
#8 tube. The flange for the slip tube is not cut all the way at the factory to prevent
damage during shipping. You will need to cut the flange the remaining portion before
attempting installation.

4. The driver’s side header slips in from the top. We found that unbolting the pillow block
that holds the steering shaft to the top of the pedal box allows more room for installing
the header. Slip the main portion of the header into place and then the #8 slip tube. You
may want to coat the slip joint with High Temp Silicone to prevent minor leakage. Watch
out for the clutch hydraulic line as you fit the header.

5. It may be necessary to remove the oil filter and cooler adaptor as well.

6. You may find that the pivot shaft for the pedals that comes through the pedal box
interferes with the header collector, in which case you will want to shorten the shaft
slightly to gain more room. We looked at 6 cars and each of these had a bit of
difference in length and it will not hurt anything to shorten it.

7. Using the supplied Doug’s Premium gaskets, bolt the header to the cylinder head using
the special header bolts and star washers. Snug each bolt before torqueing to 25 ft. lbs.
(for Iron heads) starting from the center and working outwards.

8. If removed re install the oil cooler adaptor and oil filter.

9. Re install the spark plugs and wires.

10. Re install the steering shaft / pillow block.

11. Connect the negative battery cable.

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.

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