Installation Manual for JBA Performance Exhaust 1655S Headers

Quick Guide for Installation

This manual provides installation instructions for JBA Performance Exhaust headers designed for 65-73 Ford Mustang and Mercury Cougar vehicles with a 351W engine swap. The 1653S model is designed for 4spd/5spd/C4/C6/AOD transmissions, while the 1655S model is specifically for 5spd transmissions with a cable clutch. Proper installation requires careful attention to motor mount clearance, Z-bar configuration, and dipstick tube positioning.

Vehicle Compatibility and Requirements

Before beginning the installation, ensure your vehicle meets the following requirements:

• Engine: 351W swap.
• Shock Tower Width: Minimum of 33 3/4 inches. It is recommended to install a C5ZZ16A052E style Export Brace to maintain this clearance.
• Motor Mounts: 1965 cars must update the motor mount frame bracket to a 66 or later version. Use D0OZ-6038-G or Sealed Power #270-2286 motor mounts for proper clearance.
• Spark Plug Boots: 90-degree boots are recommended on all cylinders.
• Bell Housings: Aftermarket bell housings will require clearancing for the header tubes.
• Fasteners: Header flange may need clearancing if using head studs or head bolts with hardened washers.

Installation Procedure

Follow these steps to install the headers:

1. Place the vehicle on a solid, flat surface with adequate lighting. Disconnect the negative battery cable. Raise the front of the vehicle, remove the front tires, and support the vehicle with large-base jack stands.
2. Disconnect spark plug wires by twisting the boots. Clean debris from around manifolds and spark plugs to prevent entry into the combustion chamber. Apply penetrating oil to all fasteners.
3. Remove the clutch equalizer bar (Z-bar) and lower rod on stick shift cars. Note that clearance may vary based on the specific Z-bar style.
4. If the vehicle has an EFI motor, unplug O2 sensors. If using a late-model oil pan with a side-mounted dipstick, remove the dipstick and grind away a small portion of the bracket to ensure clearance.
5. Remove the stock manifolds, gaskets, and any remaining carbon deposits from the head surface.
6. Bolt the header to the head using the supplied gaskets, bolts, and washers. Apply anti-seize to bolts if installing on aluminum heads. Tighten evenly, working from the center outwards.
7. Reinstall spark plug wires and looms, ensuring no wires rest against header tubes. Reinstall the battery cable.
8. Connect the JBA H Pipes and exhaust system.
9. Start the engine, warm it up, and check for leaks. Shut off the engine, let it cool, and re-check all fasteners for tightness.

Maintenance

All tubular headers require periodic maintenance. Regularly check and retighten the header bolts to ensure a proper seal and prevent leaks.