Corporate Office: PerTronix Inc. 440 E. Arrow Highway, San Dimas, California 91773 * Phone 909.599.5955 * FAX 909.599.6424 * www.dougsheaders.com
HEADER INSTALLATION INSTRUCTIONS
D626
67-70 FORD MUSTANG & COUGAR, 390-428
NOTE: Requires Power Steering Bracket P/N H7609
NOTE: Will only fit 16 bolt F.E. cylinder heads with the top four exhaust bolt holes in line. Header will not
seal properly on heads with the end upper bolts lower than the center bolts.
NOTE: Will not fit Cobra Jet models
©
PerTronix
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. 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
DISASSEMBLY / ASSEMBLY
LEFT SIDE:
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. Unbolt the headpipes (both sides) from exhaust manifolds and mufflers and remove.
5. Remove the power steering ram from the frame.
6. Unbolt the idler arm from the frame.
Part No. 0110-003079 Page 1 of 3 rev. 1 11-19-13 DSL
7. Remove the clutch linkage and center bolt from the motor mount.
8. Jack up the engine about 2 inches. Be sure to use a board between the pan and jack.
9. Remove both halves of the motor mount.
10. Remove the stock exhaust manifold.
11. Clean the head surface of any carbon deposits or other foreign material.
12. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the header
side of the supplied gasket and glue it to the header. Masking tape can be used to help
stick the gasket to the manifold.
13. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the header
side of the gasket.
14. Apply anti-seize to the supplied header bolts.
15. Starting from below, work the header up through the chassis into position over the
exhaust ports.
16. With the header loose, replace the clutch linkage.
17. Start all the header bolts (most restricted first) and tighten evenly.
18. Replace both halves of the motor mounts, lower the engine and replace the center bolt
in the mount. Note: On AUTOMATIC TRANS MODELS: If the L-3 tube contacts the
bellhousing between its 3rd and 4th bends, re-form for clearance (See Figure 1).
19. Do not reinstall the power steering ram or idler arm until the right side is installed.
RIGHT SIDE:
1. Remove the stock exhaust manifold and starter.
2. Remove the center bolt from the motor mount and raise the engine about 2”. Be sure to
use a board between the pan and jack.
3. Clean the head surface of any carbon deposits or other foreign material.
4. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the header
side of the supplied gasket and glue it to the header. Masking tape can be used to help
stick the gasket to the manifold.
5. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the header
side of the gasket.
6. Apply anti-seize to the supplied header bolts.
7. Starting from below, work the header up through the chassis into position.
8. With the header loose, reinstall the starter.
9. Start all the header bolts (most restricted first) and tighten evenly.
10. Lower the motor and replace the center bolt in the motor mount.
11. Replace the power steering ram with the purchased H7609 Power Steering Bracket.
12. Reinstall the idler arm. If the idler arm bolts contact the header tubes, either cut off the
ends of the bolts or use washers (under the bolt heads) to shim the bolts further toward
the outside of the frame.
13. Bolt the supplied reducers to the collectors. Cut the existing headpipes to length and weld
the reducers to them.
14. Connect the negative 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.
Part No. 0110-003079 Page 2 of 3 rev. 1 11-19-13 DSL
NOTE: Check the bolts periodically to make sure they have not loosened. Re-tighten
Weld
Joint
AUTOMATIC TRANSMISSIONS ONLY
Re-form the L-3 tube as needed for
clearance of the bell housing
L-3
Figure 1
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 Left side header
1 Right side header
2 Header gasket
2 Reducer gasket
32 Bolt, header, flanged, 3/8”-16 x 1”
38 Lock-washer, 3/8”
6 Hex head cap screw, 3/8”-16 x 1-1/4”
6 Nut, hex, 3/8”-16
Part No. 0110-003079 Page 3 of 3 rev. 1 11-19-13 DSL
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