PerTronix JBA Exhaust 1961S - 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 installation.
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 fasten-
ers to 35 ft./lbs.
8. On 2002 and newer Dodge Rams: You will need to relocate the heater hoses and heater lines
in place. Disconnect the fasteners holding the claps in place and the rotate the lines outward so
that they are not in close proximity to the new header. The lines should rest against the A/C re-
ceiver/dryer on the firewall. Secure the heater lines in place on the A/C receiver/dryer using the
supplied cable ties
8a Using the stand-offs provided, raise the fuel lines on driver’s side, and heater hose/wire loom
on passenger side. Be sure to clean the stud on the valve cover. Hold down, add a dab of RTU
silicone, and slip them on.
8b. 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.