PerTronix Dougs Headers D4476 - Manual (Page 2)

Part No. 0110-003031
Page 2 of 3
REV.2 3-5-13 DSL
6. Unbolt and remove the connector pipes.
7. Remove both front wheels.
8. Remove any wire harness or component that is attached to the inner fender panels.
9. Remove both inner fender panels. They are held in by 6 plastic rivets and 2 plastic panel
retainers on each side. Use
an 1/8” drill bit and drill out the plug in the center of each rivet
and then remove them from the fender panel. Pry out the plastic panel retainers.
10. On 4 WD models remove the front drive shaft.
11. Remove the lower steering shaft bolt; lift the steering shaft up to remove it from the
steering box. Move the lower steering shaft on top of the frame to allow clearance for
removal of the stock manifold and installation of the header.
12. On th e driver’s side, unclip the shift cable from the mounting clip on the bell housing.
Remove the clip from the bell housing and move it to the empty bottom hole on the bell
housing. Replace and tighten the bolt where the clip was originally and mount the clip in
the lower hole utilizing the supplied 3/8
” x 1 ¼” bolt, lock-washer, and nut. Do not put the
shift cable back into the clip at this time.
13. Remove the exhaust manifold heat shields.
14. Remove the stock exhaust manifolds.
15. Remove all the exhaust manifold studs from the cylinder heads
16. Clean the cylinder heads. Make sure that all residue is removed and the mounting surface
has no carbon or gasket material remaining.
ASSEMBLY
1. Match the header gaskets with the appropriate header. Make sure that the EGR port on
the header is aligned with the gasket.
2. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the header side
of the header gaskets. Stick the gasket to the appropriate header. Masking tape can be
used to help hold the gaskets to the headers.
3. Apply a THIN film of Ultra Copper Hi-Temp Sensor-Safe Silicone Sealer to the cylinder
head side of the header gasket.
4. Install both headers utilizing header bolts (with a small amount of anti-seize) and lock
washers supplied. Install all the bolts finger tight then tighten the bolts evenly to about 25
foot pounds of torque.
5. Install the steering shaft back onto steering box, install the lock bolt and tighten.
6. Install the shift cable into its clip on the bell housing.
7. On 4 WD vehicles, install the front drive shaft.
8. Install the inner fender panels using 16 new plastic push in *Panel Retainers
(Dorman
®
, Part No. 799-135 or their equivalent). These are available
at most auto parts supply stores.
9. Reattach any wires and/or components that were attached to the inner fender panels.