PerTronix D923 User Manual

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

X-PIPE INSTALLATION INSTRUCTIONS

D923

99-04 FORD MUSTANG, 4V, DOHC, USING DOUGS HEADER D6681

PerTronix

market. In 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. 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 and X-Pipes, 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 X-Pipe.

©

thanks you for choosing

DOUG’S HEADERS

, the best fitting, highest quality header on the

BEFORE STARTING

We recommend welding all pipe slip joints. If no welding equipment is available at the

time of installation, use the furnished clamps to secure the pipes until they can be
welded. If you are not going to weld the slip joints, apply a liberal amount of Ultra
Copper Hi-Temp Sensor-Safe Silicone Sealer to the joints to further ensure a proper

seal.
This X-Pipe is designed to fit with Doug’s Header Part No. D6681 only!
This X-Pipe will attach to a stock Ford exhaust or catalytic converter.

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 O2 sensors and hang up out of the way until the X-Pipe is installed.

4. Remove existing manifolds and related exhaust system.

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ASSEMBLY

1. Install Doug’s Header Part No. D6681 per instructions.

2. Install the X-Pipe assembly to the headers.

3. Install hangers in stock rubber mounts and tighten clamps.

4. Connect to exhaust system and tighten all bolts.

5. Tighten all the bolts.

6. Reinstall the O2 sensors.

7. 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.
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.

Double-check the tightness of all bolts including brackets and accessories.

PARTS LIST

Qty Description

1 X-Pipe
1 Connector Pipe
2 3” T-bolt clamps
1 2-1/2” T-bolt clamp
4 7/16” lock-washers
4 Nut, hex, 7/16”-14
4 Screw, cap, hex head, 7/16”-14 x 2-1/2”

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