Installation Manual for JBA Performance Exhaust 1683S Headers

Quick Guide from the Manual

This document provides instructions for installing JBA Performance Exhaust 1683S headers on 2015-2020 Ford F-150 5.0L V8 vehicles. The process involves removing the factory exhaust manifolds, preparing the engine bay, and installing the new headers. Always ensure the vehicle is cool before starting and use proper safety equipment like jack stands.

Preparation and Safety

Before beginning the installation, ensure you have all parts listed in the parts list. Work on a lift if available; otherwise, raise the vehicle and support it on quality jack stands on level ground. Do not rely on a jack alone. Allow the vehicle to cool, disconnect the battery, and spray penetrating oil on all hardware and fittings to be removed. Clean the sealing surface on the head of any old gasket debris or carbon build-up.

Parts List

• (1) Driver’s Side Header Assembly
• (1) Passenger’s Side Header Assembly
• (2) Header flange gaskets
• (16) 10-1.25mm Header bolts
• (16) 10mm Lock washers
• (4) 3/8-16 x 2.5” Collector Bolts
• (4) 3/8-16 Nuts
• (4) 3/8” Lockwashers
• (1) CARB EO Sticker

Passenger Side Installation

1. From underneath the vehicle, unbolt the factory exhaust system from the exhaust manifold collectors. Pry the exhaust system back about 1/2” to gain workspace.
2. Remove the passenger side front tire and inner fender panel.
3. Place a jack with a board between the jack and the oil pan underneath the motor. Remove the two 21mm motor mount nuts and raise the engine approximately 1”. Unplug the O2 sensor.
4. Remove the nuts and studs attaching the manifold to the head. Remove the manifold.
5. Remove the gasket and any gasket material or carbon deposits from the head surface.
6. Remove all factory exhaust studs.
7. Remove the O2 sensor from the factory manifold and install it into the new JBA Header using a small dab of sensor-safe anti-seize.
8. Slip the header into place through the fenderwell. Apply anti-seize to the header bolts, install the gasket, and secure with supplied header bolts and star washers in an alternating sequence.
9. Lower the motor and tighten the motor mount bolts. Plug the O2 sensor back into the harness.
10. Install the inner fender panel and front wheel.

Driver's Side Installation

1. From under the hood, remove the top two forward exhaust manifold nuts.
2. Place a jack with a board between the jack and the oil pan underneath the motor. Remove the 24mm motor mount bolt and jack the motor up approximately 1”. Remove the three 13mm motor mount plate bolts from the block and remove the plate. Unplug the O2 sensor.
3. Remove the remaining 6 nuts attaching the manifold to the head. Remove the manifold and all eight studs.
4. Clean the head surface of gasket material and carbon deposits.
5. Slip the header into place from underneath the truck. Apply anti-seize to the header bolts, install the gasket, and secure with supplied header bolts and star washers in an alternating sequence.
6. Reinstall the motor mount plate to the block and tighten the 3 13mm bolts. Lower the motor and reinstall the 24mm motor mount bolt.
7. Remove the O2 sensor from the factory manifold and install it into the new JBA Header using a small dab of sensor-safe anti-seize.
8. Apply a small amount of O2 sensor-safe RTV silicone around the flares on the factory exhaust system, then reconnect the factory catalytic converters and exhaust system to the new headers using the supplied 3/8-16 x 2-1/2” collector bolts, nuts, and lock washers.
9. Plug the O2 sensor back into the harness.

Final Steps

Check to make sure that all wiring, fuel lines, transmission cooler lines, brake lines, and hoses are clear of the headers or any exhaust components and reroute or relocate those components as necessary. Reconnect the battery. Start the engine, check for leaks, and test drive. Let the engine cool and then re-torque the header bolts.

Warranty Information

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 resulting from collision, improper installation, off-road use, road hazards, or the use of exhaust insulating wrap is not covered.