PerTronix JBA Exhaust 1949S-1 - Manual (Page 3)

1. Place vehicle in a location where the floor is solid and flat, with adequate lighting. Do not attempt to work
on a hot engine. Heat causes metal to expand and makes removal of fasteners difficult at best. Disconnect the
battery cables from the battery. Raise the front of the vehicle to obtain adequate access to the bottom exhaust
manifold flanges. Use large-base jack stands to support the vehicle. Do not rely on the jack! Block the tires to
prevent the vehicle from rolling off the jack stands.
2. Spray WD-40 or some type of penetrating oil on all accessible fasteners and fittings before attempting to
remove them.
3. From underneath the vehicle disconnect the Y-pipe from the exhaust manifold.
4. Remove the nuts attaching the heat shields to the factory manifolds. Then unbolt and remove the manifolds.
5. Using a gasket scraper, remove all carbon deposits and high spots from head surface. At this time apply a
high temperature sealer to exhaust pipe flare in order to avoid problems due to lack of space later on in the in-
stallation.
6. Using the supplied gaskets and fasteners install the new headers. Be sure to prepare the new header bolts by
applying a small amount of anti-seize to the threads before installing. Torque the fasteners to 23 ft./lbs.
7. Reconnect the exhaust system to the headers using the supplied hardware. Torque the fasteners to 35 ft./lbs.
8. On 2002 and newer Dodge Rams: You will need to relocate the heater hoses and heater lines in place. Discon-
nect the fasteners holding the claps in place and the rotate the lines outward so that they are not in close proxim-
ity to the new header. The lines should rest against the A/C receiver/dryer on the firewall. Secure the heater lines
in place on the A/C receiver/dryer using the supplied cable ties
8. Check to make sure there is adequate clearance on plug wires, battery cables, wire looms, brake lines, etc.
9. Re-connect battery cables.
10. Recheck everything!
11. Start the engine and let it warm up. Check for leaks. Shut engine off and let it cool down. Check to make
sure all fasteners are tight.
12. All tubular headers require maintenance including periodically checking and retightening of the header
bolts.
Parts List:
(1) Driver’s Side Header Assembly
(1) Passenger’s Side Header Assembly
(16) 8mm -1.25 x 25mm header bolts &lock washers (Torque to 23 ft/lbs. with anti-seize on threads)
(2) Header gaskets (Header to Head flange)
(4) 3/8” x 2 1/2” Collector Bolts, Nuts & Washers. (Torque to 35 ft./lbs.)
(2) Cable ties