PerTronix D6621 User Manual

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

HEADER INSTALLATION INSTRUCTIONS

D6620 & D6621

1999 - 2002 Ford F250/F350 Pickups and Excursions 6.8L V10

PART NUMBER: D6620 & D6621

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.

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thanks you for choosing

DOUG’S HEADERS

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

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 both front wheels.

5. Unbolt and remove the front inner fender panels. There are various electrical
connectors as well as some other components that must be removed in order to
facilitate the removal of these panels. There is no need to disconnect any of these
components. They can remain in place and be reinstalled during the assembly process.

6. Unplug the O2 (oxygen) sensor wires and remove the O2 sensors. Use care to not
damage the wire or sensors. Do not lose the gasket.

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7. Remove the factory Y pipe by disconnecting it from the exhaust manifolds and the three
bolt flange at the front of the catalytic converter.

8. Remove the dipstick and tube. The dipstick tube is attached to the block with a small
bolt and has a small o-ring that may remain in the block when the tube is removed. It is
necessary to remove the o-ring from the block and place it back onto the tube for
reinstallation later. If this o-ring is damaged, replace it at this time.

9. If your vehicle is equipped with EGR, unscrew the EGR tube with an 1 ¼” wrench.

10. Use a 10mm socket or wrench to remove the exhaust manifolds. Note: All of the factory
studs must be removed from the cylinder heads anyway so if any of the studs come out
when you are removing the nuts, leave them out.

11. Remove any remaining studs and clean the head surface. Be very careful when using
any sort of metal scraper as the heads are aluminum and the surface can be damaged
very easily.

ASSEMBLY

1. Install the headers and secure them temporarily in place with a couple of bolts to
determine proper fit.

2. Once you have determined proper fitment, remove the headers. Apply a THIN film of
Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to each side of the header flange
gaskets around each of the exhaust port openings.

3. Stick the gaskets onto the headers; small pieces of masking tape can be used to help
hold the gaskets to the headers.

4. Apply a small amount of anti-seize to the header bolts supplied with the headers.

5. Install the headers and hold them in place by installing bolts, with lock washers, in the
end holes of the headers. Leave these bolts loose at this time

6. On EGR equipped vehicles, attach the EGR tube to the driver’s side header fitting.

7. Install the remaining header bolts, with lock washers and tighten evenly to a final torque
of approximately 25 ft. lbs.

8. Slip the two halves of the y-pipe together utilizing the supplied clamp but do not tighten
the clamp at this time.

9. Apply a small amount of copper Hi-temp silicone to each side of the catalytic converter
gasket and install it on the 3-bolt flange on the front of the catalytic converter.

10. Install y-pipe assembly over the studs on the front of the catalytic converter. Fit to the
headers using the donut gaskets supplied. Reinstall the stock catalytic converter nuts.

11. Attach the y-pipe assembly to the headers using the 6 bolts, washers, and nuts
supplied and hand tighten.

12. Adjust the y-pipe for best fit and tighten all the joints evenly.

13. Tighten the y-pipe clamp.

14. Apply a small amount of anti-seize to the threads of the O2 sensors. Be careful not to
get any anti-seize onto the element of the sensors.

15. Install and tighten the O2 sensors.

16. Replace the two original O2 sensor harnesses with the two new (longer) O2 sensor
extension harnesses.

17. Secure O2 sensor wires away from exhaust pipes/linkage that might entangle the wires.

18. Install both inner fender panels and reattach any components that were attached to the
panels originally.

19. Install the front wheels and torque the lugs to factory specifications.

20. Connect the battery cable.

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