JBA 1961S-3 User manual

Installation Instructions
Dodge Ram 1500 5.7 HEMI
1961S-3 2019-20 5.7 DT
Read all instructions carefully before attempting installation.
Rev. 1 1-8-20 DSL
Corporate Oce: PerTronix Inc. 440 E. Arrow Highway, San Dimas, California 91773 * Phone [phone] • FAX [phone]
!
Headers shown are earlier year model and
appear slightly dierent.

PerTronix© thanks you for choosing JBA HEADERS, the best tting, highest
quality header on the market. 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 aect 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 dierent engines or aftermarket cylinder
heads.
Attention Customers breaking in new engines: Due to the extreme heat gener-
ated 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 instal-
lation. 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 cor-
rectly,theraisedbeadaroundeachportincreasesthepressureexertedonthegasket
directly adjacent to the port and eectively prevents leaking gaskets. It is normal
for the ange to be raised o 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 pos-
sible performance out of their pair of headers.

1. Place vehicle on a four post lift. If a lift is not available, 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 dicult at best. Disconnect the
battery cables from the battery. Raise the front of the vehicle at least 3’. Use large-base jack
stands to support the vehicle. Do not rely on the jack! Block the tires to prevent the vehicle
from rolling o the jack stands.
2. Spray penetrating oil on all accessible fasteners and ttings before attempting to remove
them.
3. From underneath the vehicle disconnect the Y-pipe from the exhaust manifolds. Discon-
nect the (4) 02 sensor plugs from the wiring harness. Disconnect the Y-Pipe from the exhaust
and remove from the truck. Support the transmission with a jack and remove the trans cross-
member. Remove the Y-Pipe from the truck and reinstall the crossmember with 2 of the bolts
to hold it in place so you can get the jack out of your way.
4. Remove the nuts attaching the heat shields to the factory manifolds. Then unbolt and re-
move the manifolds. Manifolds will remove from underneath the truck. Remove the Clip Nuts
from the exhaust end of the manifolds and install them on the JBA headers.
5. Using a gasket scraper, remove all carbon
deposits and high spots from head surface.
6. Using the supplied gaskets and fasteners install
the new headers. The bolt in the oil dipstick
location will reuses the OEM bolt. Use the supplied
spacer. Be sure to prepare the new header bolts by
applying a small amount of anti-seize to the threads
before installing. Tighten bolts evenly starting from
the center out.
7. Support the transmission once again and remove the Crossmember. Slip the Y-Pipe into
position and reinstall and tighten the
crossmember.
8. Reconnect the Y-Pipe to the exhaust system
and connect to the headers using the original
bolts. Torque the fasteners to 35 ft./lbs.
8. Reroute the ABS wiring on the right side and
zip tie it to the heater hoses, making sure that
the wire and the hoses are up away from the
new JBA header. You need at Least 1” of
clearance from the header.

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, o󰀨-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 side header
(1) Passenger side header
(2) Head ange gaskets
(16) Header Bolts
(16) Header Lock Washers
(1) Oil Dipstick Spacer tube
10. Reconnect the battery cables.
11. Start the engine and let it warm up. Check for leaks. Shut engine o and let it cool down.
Check to make sure all fasteners are tight. Re-Tighten the header bolts after about the rst
100 miles. Check the clearance between the ABS wires and heater hoses and the headers.
12. All tubular headers require maintenance including periodically checking and retighten-
ing of the header bolts.