JBA 1674S User manual

Installation Instructions
and Warranty Information
Read all instructions carefully before attempting installation.
Rev. 06/11
Corporate Ofce: PerTronix Inc. 440 E. Arrow Highway, San Dimas, California 91773 * Phone [phone] • FAX [phone]

.
Part# 1674S (Passenger Side EGR)
Part# 1674S-1 (Driver Side EGR)
Part# 1674S-2
For 1997-2006 Vehicles:
The product accompanying this document has been granted a California Air Resources Board (CARB)
exemption, an “E.O.” number, or is a direct or consolidated replacement part. It is 50-state legal, per the
manufacturer’s application guide.
These headers retain all O.E.M. emissions equipment and are covered under the C.A.R.B. E.O. #D-216-29
Included in this kit you will nd a label that is required to aid in passing the California smog check program.
For 2007 Vehicles:
WARNING: The product accompanying this document is legal only for off-highway use (except in California
or states that have adopted California emission standards), racing use or for use on pre-emission-controlled
motor vehicles/motor vehicle engines (pre-1966 domestic vehicles certied to California standards, pre-1968
domestic vehicles certied to federal standards and all pre-1968 foreign vehicles), per the manufacturer’s
application guide.
JBA Headers for 1997-2007 Ford Ranger,
Explorer, and Sport Trac with 4.0L SOHC V-6

PerTronix© thanks you for choosing JBA HEADERS, the best tting, highest quality header on the mar-
ket. In order to realize the full potential of our good t, 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 ange. 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 conguration of the frame, and/or the installation of different engines or after-
market cylinder heads.
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 character-
istics 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.
JBA uses sealing beads on all its headers. We have found that when installed correctly, the raised bead around
each port increases the pressure exerted on the gasket directly adjacent to the port and effectively prevents leak-
ing gaskets. It is normal for the ange to be raised off the cylinder head the thickness of the sealing bead. It is
important when installing the header, to install all bolts loosely, then tighten evenly to ensure the at installation
of the ange. The torque sequence from one ange to another will vary, but generally every bolt on a header
should be rst t snug, starting from the inside of the ange working out, alternating from top to bottom so
that the bolt connects the ange to the manifold to the point where they barely touch. Second, using the same
inside-out pattern, tighten each bolt until nished. This method will help prevent leakage and will give the user
the best possible performance out of their pair of headers.
1. Place vehicle in a location where the oor is solid and at, with adequate lighting. Do not attempt to work
on a hot engine. Heat causes metal to expand and makes removal of fasteners difcult at best. Disconnect the
battery cables from the battery. Raise the front of the vehicle to obtain adequate access to the bottom exhaust
manifold anges. 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 ttings before attempting to
remove them.
3. From underneath the vehicle, loosen the bolts connecting the exhaust system to the exhaust manifolds. Pry
the exhaust system back about 1/2” to gain workspace.

Note: Ford 4.0L sohc V-6 engines can have the EGR connection located on the front of the driver side manifold
(use P/N 1674-1) or on the rear of the passenger side manifold (use P/N 1674).
4. For P/N 1674S: From above, loosen the EGR tube at the rear of the passenger side manifold.
For P/N 1674S-1: From above, loosen the EGR tube at the front of the driver side manifold.
5. On the driver’s side, remove the fasteners attaching the manifold to the head and remove the manifold.
6. The dipstick must now be removed. It has a separate mounting bolt on the head and uses an O-ring seal at the
bottom. Use care to protect the O-ring.
7. On the passenger side, remove the fasteners attaching the manifold to the head then remove the manifold.
8. Unbolt the bracket and cable from the passenger side, above the exhaust manifold. Retain the larger bolt for
reuse.
9. Using a scraper remove all carbon deposits and high spots from head surface, use care not to gouge the heads.
Driver’s Side Header
Note: Slip the dipstick into the driver’s side header and into the block before bolting the header to the head.
For 1674S-1, start the EGR tube on the driver side header before you start the header bolts.
10. Apply a small amount of Hi-temp RTV (sensor safe) to the exhaust pipe are then install the driver’s side
header. Attach the headers using the supplied bolts and gaskets. Apply a small amount of anti-seize to the
threads of the bolts before tightening then torque to 13 ft/lbs.
Passenger Side Header
Note: For 1674S, start the EGR tube on the passenger side header before you start the header bolts.
11. Apply a small amount of Hi-temp RTV (sensor safe) to the exhaust pipe are then install the passenger side
header through the wheel well. Attach using the supplied bolts and gaskets. Apply a small amount of anti-seize
to the threads of the bolts before tightening then torque to 13 ft/lbs.
12. Re-attach the cable and bracket on top of the header using the (1) original bolt and the (2) additional bolts
supplied with this kit.
13. Re-connect the exhaust system to the new headers using the hardware provided.
14. Check to ensure that there is adequate clearance on all brake lines, wire looms, a/c lines, etc.
15. Reconnect the battery.
16. Re-check everything!
17. Start the engine, check for leaks and test drive. Then let engine cool and then re-torque the header bolts.
18. Periodically check and retighten the header bolts.

LIMITED ONE YEAR WARRANTY
All JBA HEADERS and exhaust products are guaranteed, to the original purchas-
er, to be free of defects in materials and workmanship for one year. This warranty
covers the replacement or repair of the product only and does not cover the cost
of removal and installation, customer applied aftermarket coatings or any discolor-
ation or corrosion of nished surfaces.
Damage or product failure resulting from collision, improper installation, off-road
use, road hazards, the use of exhaust insulating wrap or like products or rust oc-
curring after installation, is not covered by the warranty. The warranty extends only
to the original purchaser.
Should a part become defective it should be returned to the original selling retailer
and must be accompanied with the sales receipt. If there is no retailer in your area,
call the factory for a return authorization and return your part prepaid to the factory
for inspection. PerTronix reserves the rights to replace or repair the alleged defec-
tive part and return the part freight collect.
Parts List:
(1) Driver’s Side Header Assembly
(1) Passenger .s Side Header Assembly
(2) Header ange gaskets
(13) 8mm -1.25 x 25mm Header fasteners w/lock washers (Torque to 13 ft/lbs)
(4) 3/8 -16 x 2 ”Collector bolts w/nuts (Torque to 35 ft./lbs)
(1) 6mm x 25mm bolt
This sticker is required to aid in passing the California Smog Check Program.
This sticker must be installed in an underhood location that is readily visible.