PerTronix D6659 User Manual

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

HEADER INSTALLATION INSTRUCTIONS

D6659

2004-2005 2&4 W/D FORD PICK-UP 5.4L 3 VALVE

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. Remove both front wheels.

4. Lay a protective covering over brakes and spindles so as not to get them dirty.

5. Remove the inner fender panels.

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

7. Remove all nuts and bolts and lower the sway bar out of the way.

8. Remove the first and second exhaust hanger brackets.

9. Support the rear of the transmission and remove the transmission cross member.

10. Disconnect the factory “Y” pipe from the exhaust manifolds and the rest of the system.

11. Disconnect all the wires from the starter and then remove the starter.

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12. Remove the two lower engine mount nuts on the passenger side only.

13. Remove the engine oil dipstick and tube.

14. Remove all exhaust manifold nuts and studs from both sides of the engine.

15. Slightly raise the passenger side of the engine and remove the exhaust manifold, and then
lower the engine back into place. Remove the driver side exhaust manifold next.

16. Clean the cylinder head surface which mates to the header. Use a gasket scraper, wire brush,
make sure that the surface is absolutely clean.

17. 4 W/D applications: Disconnect front driveshaft at differential and move out of the way during
header install.

ASSEMBLY

1. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the header side of
the 4 supplied gaskets and glue them to the headers. Masking tape can be used to help stick
the gasket to the manifold.

2. Apply anti-seize to all header bolts being used.

3. Raise the passenger side of the engine again.

4. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the engine side of
the 2 passenger side header gaskets and install the header from below the vehicle. Using two
header bolts and lock-washers supplied, install one of the bolts in the front bolt hole and the
other in the rear bolt hole. Install these bolts loosely to support the header.

5. Lower the engine into place and reinstall the engine mount nuts, tighten accordingly.

6. Install the remaining bolts and lock washers on the passenger side and then tighten evenly.

7. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the engine side of
the 2 driver side header gaskets and install the header from below the vehicle. Just start the
front header bolt to support the front of the header.

8. Install the remaining bolts and lock washers on the driver side.

9. Install engine oil dipstick tube and dipstick.

10. Tighten the header bolts evenly to a final torque of approximately 25 ft. lbs.

11. Reinstall the starter and starter wires.

12. Apply a small amount of gasket sealer to the header donut. Loosely install the factory “Y” pipe.

13. Adjust the “Y” pipe for best fit and tighten all the joints evenly.

14. Reinstall the sway bar, transmission cross member, tighten all the nuts and bolts accordingly.

15. Reinstall both exhaust hangers.

16. Install both inner fender panels.

17. Install the front wheels and torque the lugs to factory specifications. (Approx. 150 ft. lbs.)

18. 4 W/D applications: Reconnect front driveshaft to differential.

19. 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 removed, make sure the dipstick is installed properly and that it has been replaced.
Double-check the tightness of all bolts including brackets and accessories.
Perform these checks again after the first 1000 miles.

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