Installation Instructions for JBA Performance Exhaust 1647S and 1647S-1

Important Information

This document provides installation instructions for JBA Performance Exhaust Cat4Ward Headers, specifically models 1647S (for 98-01 Ranger 3.0 V6 with EGR) and 1647S-1 (for 02-08 Ranger 3.0 V6 without EGR). Always ensure the vehicle is cool before starting and use proper safety equipment, such as a lift or quality jack stands.

Safety and Preparation

Before beginning the installation, ensure you have received all parts listed in the parts list. If you have concerns, contact the manufacturer before proceeding. Work smart and safe; 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. Disconnect the battery and spray a penetrating oil on all hardware and fittings that need to be removed.

Parts List

• Driver’s Side Header Assembly
• Passenger’s Side Header Assembly
• Header flange gaskets
• 12x 8mm-1.25 x 25mm Header Bolts
• 12x 8mm Internal Lock Washers
• 4x 7/16 x 2 1/4” Collector bolts
• 4x 7/16” Hex Nuts
• 4x 7/16 Lock Washers
• 4x 7/16 Flat Washers
• CARB EO sticker

Installation Steps

1. From underneath the vehicle, loosen the bolts connecting the exhaust system to the exhaust manifolds. Move the exhaust system back about 1/2 inch to gain work space.
2. From above, loosen the air tube at the front of the driver side manifold.
3. Remove the fasteners attaching the driver’s side manifold to the head and remove the manifold.
4. Remove the dipstick. It has a separate mounting bolt on the head and uses an O-ring seal at the bottom; take care to protect the O-ring.
5. Remove the fasteners attaching the passenger’s side manifold to the head and remove the manifold.
6. Remove the gaskets and any gasket material or carbon deposits from the head surface. Use a gasket removal agent if necessary. Be careful not to get debris into ports or spark plug holes. Clean excess carbon deposits from the exhaust system mating flange.
7. Slip the dipstick into the driver’s side header and guide it into the block as you maneuver the header into place. On 98-01 models, start the EGR tube before bolting the header to the head.
8. Apply anti-seize to the header bolts if installing on aluminum heads. Bolt the driver’s side header to the engine using the supplied gaskets, bolts, and lock washers. Tighten the bolts evenly, starting from the center and working outward.
9. Install the passenger side header through the wheel well. Apply anti-seize to the header bolts if installing on aluminum heads. Bolt the header to the engine using the supplied gaskets, bolts, and lock washers. Tighten the bolts evenly, working from the center out.
10. Apply a thin coat of high-temperature, sensor-safe silicone on the header collector domes and re-connect the exhaust system to the headers using the provided hardware.
11. Check that all bolts are tight. Ensure all wiring, fuel lines, transmission lines, and brake lines are clear of the headers and exhaust; relocate as necessary.
12. Reconnect the battery.
13. Start the engine, check for leaks, and test drive. Let the engine cool and then re-torque the header bolts.

Maintenance

Periodically check and retighten the header bolts to ensure they remain secure.