Applicable Vehicle Models
These JBA Cat4Ward® Headers are designed for the following Ford vehicles:
- 1627S: 1987-95 F-150/Bronco 5.0 L
- 1627S-1: 1996 F-150/Bronco 5.0L
- 1628S: 1986-96 F-150/F-250/Bronco 5.8L
- 1628S-2: 1993-95 5.8L Lightning
- 1628S-3: 1987-96 F-250 5.8L w/Port Air Inj.
- 1628S-4: 1987-96 F-250 5.8L w/Dual Air Inj.
(Note: The specific header part number is stamped in the flange.)
Before You Begin
PerTronix thanks you for choosing a JBA Performance Exhaust Product. To realize the full potential of JBA's engineering and excellent fit, please read and understand these instructions completely prior to starting the installation.
Parts Check: Verify that you have received all the parts listed on the parts list. If you have any concerns, please contact PerTronix before continuing.
Work Smart – Work Safe! Most header and exhaust installations are best performed on a lift. If a lift is not available, raise the vehicle and support it on quality jack stands on level ground. Do not rely on a jack alone!
Sealing: JBA headers use sealing beads on the flanges. The raised bead creates a better seal, virtually eliminating leaks if installed properly. It is important to install all header bolts lightly snug and then tighten them to factory torque specifications, starting in the center and working outward.
Preparation: Before starting, allow the vehicle to cool, disconnect the battery, and spray a penetrating oil on all hardware and fittings that will need to be removed. Once you remove the manifold, clean the sealing surface on the head of any old gasket debris or carbon buildup.
Installation Steps
- Unbolt the Y-Pipe assembly from the collector flanges of the factory headers.
- Unbolt the dipstick tube bracket from the engine and remove it.
- Unbolt the Driver's side exhaust manifold and remove it. Remove the old gasket and any gasket material or carbon deposits that remain on the head surface.
- Apply anti-seize compound to the header bolts, especially if installing on aluminum heads. Bolt the Driver's side header onto the head using the supplied header gasket, header bolts, and lock washers. Tighten bolts from the center outward.
- Dipstick Tube Bracket Modification: On some vehicles, modification of the dipstick tube bracket is required. Grind the bracket to allow it to fit between the header tube and the header bolt. On some models, the use of a spacer along with a stock manifold stud allows the dipstick to be re-attached with no modification. Clean all grease/oil from the outside of the dipstick tube. When ready to re-install the dipstick tube, apply a small amount of silicone sealant to the outside of the dipstick tube where it slip-fits into the engine.
[Diagram Description: An illustration detailing the dipstick tube and its bracket, indicating a section to be removed or modified for clearance with the header tube.]
- Unbolt the passenger side manifold and EFI plenum support.
- On 1986 & 1996 5.0L engines: remove the O2 sensor from the fitting on the rear of the manifold.
- On 1986-96 5.8L engines without air injection: remove the EGR fitting from the front of the passenger side exhaust manifold.
[Diagram Description: Diagrams illustrating modifications needed for the plenum support bracket, showing areas to trim or bend. Also shows an adapter bracket for the secondary air injection tube.]
- The tube running past the headers is the catalytic converter's secondary air injection tube. On 1986 & 1996 5.0L engines, the tube has one bracket that bolts to the head via the factory exhaust manifold bolt. On 1987-95 5.0L engines, the tube has two brackets.
- Secondary Air Injection Tube Modifications:
- 1986-96 5.8L engines w/o air injection: The secondary air injection tube has a plastic diverter valve towards the rear. This valve must be kept away from the headers. To do this, the tube must be moved outward by using the steel extension bracket (included) to allow the air injection tube to stand off from the headers. The bracket bolts to the head where the secondary air injection tube originally was attached. The secondary air injection tube is then bolted to the adapter bracket.
- 1986-95 5.0L engines: The secondary air injection tube can be re-attached in the factory location. As with the dipstick tube, the use of a spacer and a stock stud allows the secondary air injection tube to be re-attached in the factory location.
- After the above modifications have been performed, remove the temporarily installed header. Remove the old gaskets and any gasket material or carbon deposits that remain on the head surface. The use of a gasket removal agent will ease the removal of any gasket material. Use care not to get debris into ports or spark plug holes. Clean excess carbon deposits from the Y-Pipe mating flange. Apply anti-seize to the header bolts if installing on aluminum heads. Bolt the header to the head using the supplied header gasket, header bolts, and lock washers. Tighten evenly from the center out. At the same time, reinstall the secondary air injection tube as discussed above in step 8a or 8b.
- On 1986 & 1996 5.0L engines: reinstall the O2 sensor on the fitting on the rear of the collector.
- On 1986-96 5.8L engines w/o air injection: reinstall the EGR fitting into the fitting welded to the front tube of the header.
- Apply a thin coating of High Temperature, Oxygen Sensor Safe, Silicone Sealant to the collector dome on each header. Attach the headers to the Y-Pipe from the underside using the supplied nuts and bolts.
- Reinstall the spark plug wires and looms, taking care not to let any wires rest against the header tubes. Reinstall the negative battery cable.
- Check that all bolts are tight. Make sure that all wiring, fuel lines, transmission lines, brake lines, etc., are clear of the headers and the exhaust, and relocate them as necessary.
- Start the engine and let it warm up. Check for leaks. Shut the engine off, let it cool, and check all bolts are tight again.
Parts List
- Driver's Side Header Assembly (1)
- Passenger's Side Header Assembly (1)
- 3/8" x 1" header bolts & lock washers (16)
- Header gaskets (Header to Head flange) (2)
- Collector Bolts & Nuts (4)
- Secondary Air Injection Tube Adapter Bracket & Fastener [1628 models only] (1)
- Dipstick/Air injection tube spacers (2)
- CARB Sticker (1)
Emissions Information
This product has been granted a California Air Resources Board (CARB) Executive Order (EO Number) Exemption. It is 50 State Legal when installed on the specified vehicle per the Manufacturer's Current Application Guide, the CARB EO, and these Installation Instructions.
[Diagram Description: A green square with a white numeral '1', signifying compliance with emissions standards.]
California Proposition 65 Warning: This product can expose you to chemicals including Lead, Nickel, Cadmium and Chromium, which are known to the State of California to cause cancer and birth defects or other reproductive harm. For more information go to www.P65Warnings.ca.gov.
[Diagram Description: A label indicating the vehicle is equipped with specific headers and referencing California Air Resources Board (CARB) Executive Orders D-57-27 and D-57-31, along with a warning for smog check visibility.]
Limited Warranty
All JBA Headers and Exhaust products are guaranteed, to the original purchaser, 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 discoloration or corrosion of finished 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 occurring 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 defective part and return the part freight collect.
