PerTronix D6677 User Manual

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

HEADER INSTALLATION INSTRUCTIONS

D6677

1994-1995 FORD Mustang, 255-302W

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. Unbolt head pipes from stock exhaust manifolds.

5. Remove smog tube, spark plug wires, spark plugs and the stock exhaust manifolds.

6. Remove power steering pump, unbolt A/C compressor and mounting bracket.

7. Remove the engine oil dipstick and tube.

8. Loosen H-Pipe at the rear joint (muffler end) to ease the header installation.

9. Replace the spark plugs finger tight so debris will not get into the cylinders while cleaning the
head surface.

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

11. After cleaning is complete remove the spark plugs again.

ASSEMBLY

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

2. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the header side of
the 2 supplied gaskets and glue them to the headers. Masking tape can be used to help stick
the gasket to the manifold.

3. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the engine side of
the left side header gasket.

4. Starting from above, work the left side header down into place.

5. Start all of the header bolts for this header but leave header loose.

6. Modify the dipstick tube bracket as shown in Figure 1.

7. Re-install engine oil dipstick tube and dipstick.

8. Install 2 bolts from exhaust system to the header using the supplied 7/16” bolts and washers
and tighten them evenly.

a. Note: On stick shift models, it will be necessary to move the clutch cable away from the

header. This can best be accomplished by bending the mounting bracket towards the
fender. Be sure cable has at least 1” of clearance from the header.

9. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the engine side of
the right side header gasket.

10. Starting from above, work the right side header down into place.

11. Start all of the header bolts for this header but leave header loose.

12. Reinstall stock smog tube to bracket with stock screw.

13. Install 2 bolts from exhaust system to the header using the supplied 7/16” bolts and washers
and tighten them evenly.

14. Tighten H-Pipe at rear joint.

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

16. Reinstall power steering pump, A/C bracket and compressor.

17. Reinstall spark plugs and plug wires.

18. Make sure all of the other fasteners are tightened.

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.
Check clearance and tightness of front driveshaft.

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