PerTronix Dougs Headers D4476 - Manual

Part No. 0110-003031
Page 1 of 3
REV.2 3-5-13 DSL
HEADER INSTALLATION INSTRUCTIONS
PART NUMBER: D4476
APPLICATION
2004-08
DODGE DURANGO 5.7L “HEMI”
PerTronix ©
thanks you for choosing
DOUG’S HEADERS, the best fitting, highest quality header on the 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. 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.
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. Remove ALL of the O
2
sensors. Use care not to damage the wires when disconnecting
from the sensors. Take care not to drop any of the sensors.
5. Cut the 2 connector pipes at the front of the Catalytic Converters. These cuts must be
made on the Converter side of the welds that holds the converter heat shields on. These
cuts must be made as close to the weld as possible, they can even be slightly into the
weld. Refer to figure 1 for exact position of the cuts.
Corporate Office: PerTronix Inc. 440 E. Arrow Highway, San Dimas, California 91773 * Phone 909.599.5955 * FAX 909.599.6424 * www.dougsheaders.com
2004 ONLY
2005-08