Installation Instructions for JBA Performance Exhaust Cat4Ward Headers 1676S / 1676S-1

Quick guide from the manual

This document provides installation instructions for JBA Performance Exhaust Cat4Ward Headers, specifically models 1676S (2004-10 Ford F-150 5.4L 3V) and 1676S-1 (2005-10 Ford F-250 5.4L 3V). Before beginning, ensure the vehicle is cool, the battery is disconnected, and you have access to a lift or quality jack stands.

Preparation and Safety

• Safety First: Always use a lift if available. If not, raise the vehicle and support it on quality jack stands on level ground. Never rely solely on a jack.
• Preparation: Allow the engine to cool completely. Disconnect the battery. Spray penetrating oil on all hardware and fittings to be removed.
• Surface Cleaning: After removing the manifold, clean the sealing surface on the head of all old gasket debris or carbon buildup. Use a scraper or gasket removal agent, ensuring no debris enters the ports.

Passenger Side Header Installation

1. From underneath, unbolt the factory exhaust system from the manifold collectors. Pry the exhaust system back about 1/2 inch to gain workspace. Spraying rubber exhaust hangers with WD-40 may assist.
2. Remove the passenger side front tire and inner fender panel.
3. Remove the starter.
4. Place a jack with a board between the jack and the oil pan under the motor. Remove the motor mount nut (under the frame) and raise the engine approximately 1 inch. Remove the bolts holding the motor mount plate to the engine.
5. Remove the nuts and studs attaching the manifold to the head, then remove the manifold.
6. Remove the gasket and clean the head surface.
7. Remove both studs from cylinder 2 and 3, and the top stud from cylinder 1.
8. Slip the header over the frame from the top.
9. Install the supplied gasket after the header is in place.
10. Re-install studs on cylinder 1 and 2 only.
11. Install supplied bolts and washers on cylinder 3.
12. Reuse factory nuts on remaining studs. Tighten fasteners in an alternating sequence.
13. Re-install the starter, bolt the motor mount plate to the motor, lower the motor, and tighten the lower mount bolts.

Driver's Side Header Installation

1. From underneath, remove the nuts attaching the manifold to the head. Remove the engine oil dipstick, noting its insertion point. Remove the manifold.
2. Remove the rear-most top manifold stud from the head.
3. Clean the head surface of gasket material and carbon deposits.
4. Slip the supplied head gasket over the studs, then install the header.
5. Install the supplied bolt and washer into the rear-most top hole. Reuse factory nuts on remaining studs. Tighten in an alternating sequence.
6. Reinstall the dipstick tube and dipstick.
7. Apply O2 sensor-safe RTV silicone around the flares on the factory exhaust system. Reconnect the factory exhaust system to the new headers using the supplied 2-1/2 inch collector bolts.
8. Verify that all wiring, fuel lines, transmission cooler lines, and brake lines are clear of the headers. Reroute or relocate components if necessary.
9. Install the inner fender panel and front wheel.
10. Reconnect the battery.
11. Start the engine, check for leaks, and test drive. Let the engine cool and re-torque the header bolts. Periodically check and retighten bolts.

Parts List

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