PerTronix D6683 User Manual

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

HEADER INSTALLATION INSTRUCTIONS

D6683

2005-2010 FORD MUSTANG, 4.6L, 3V

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

Note 1: Remove the O2 sensors from the factory H-pipe and label each one for

correct positioning later)

Note 2: The aluminized X-pipe kit (D924) is a direct slip on component, designed to

fit with the D6683 header. The D6683 header is also designed to allow for re­use of the factory H-pipe by cutting the H-pipe 4” in front of the hanger
bracket and having a muffler shop expand it to slip over the header.

Part No. 0110-003075 Page 1 of 3 Application date Rev 2-24-11 DSL

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. Remove the factory H-pipe.

5. Remove the left side stock manifold and all studs.

Very Important: Use a 5mm hex socket for the studs.

6. With the wheels straight and steering column in the locked position, remove the upper
bolt on the steering shaft at the rack and pinion (See Photo A).

7. Using a small amount of force, pull the shaft up about ½” and back to disengage it from
the steering shaft universal joint.

8. Clean the head surface of any carbon deposits or other foreign material.

9. 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.

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

11. Apply anti-seize to the stock header bolts.

12. Insert the left side header into the engine bay from below. Install the bolts.

13. Tighten all bolts evenly to ensure a proper gasket seal to the head.

14. Re-install the O2 sensors in the correct position as removed (O2 extension harnesses
supplied).

15. Re-install the steering shaft into the coupler. Slide the shaft down into the socket and
tighten the bolt.

RIGHT SIDE:

1. Remove the right side stock manifold and all studs.

Very Important: Use a 5mm hex socket for the studs.

2. Clean the head surface of any carbon deposits or other foreign material.

3. 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.

4. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the header

side of the gasket.

5. Apply anti-seize to the stock header bolts.

6. Insert the right side header into the engine bay from below. Rotate the header so the

flange surface is up and the tail of the header is down to insert into the engine bay.

7. Install the bolts.

8. Tighten all bolts evenly to ensure a proper gasket seal to the head.

9. Connect to exhaust system.

10. Re-install the O2 sensors in the correct position as removed (O2 extension harnesses

supplied).

11. Connect the negative battery cable.

Part No. 0110-003075 Page 2 of 3 Application date Rev 2-24-11 DSL

PHOTO A

START THE ENGINE

Start the engine and allow it to warm up to operating temperature. Check for any unusual
noises or exhaust leaks. If everything is OK, stop the engine and tighten all bolts while
the engine is still warm.
NOTE: Check the bolts periodically to make sure they have not loosened. Re-tighten
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
4 Header gasket (1 set per side)
16 Bolt, header, flanged, (8mm, 1.25mm x 25mm)
16 Lock-washer, 3/8”
2 O2 sensor extension cables

Part No. 0110-003075 Page 3 of 3 Application date Rev 2-24-11 DSL