JBA Performance Exhaust Cat4Ward Headers Installation Manual

Quick guide from the manual

This document provides installation instructions for JBA Cat4Ward Headers on various Ford vehicles (1997-2004). Before starting, ensure the vehicle is cool and the battery is disconnected. Use a lift or quality jack stands for safety. The process involves removing the factory exhaust manifolds, installing the new headers with provided gaskets and hardware, and performing a post-installation check for leaks and proper clearance.

Preparation and Safety

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.

• Allow the vehicle to cool completely before starting.
• Disconnect the battery.
• Spray penetrating oil on all hardware and fittings that need to be removed.
• Clean the sealing surface on the head of any old gasket debris or carbon build-up.

Removal of Factory Manifolds

1. Remove the front wheels.
2. From underneath the vehicle, loosen the bolts connecting the exhaust system to the exhaust manifolds. On 4X4 models, disconnect the front drive shaft by removing the 4 bolts on the companion flange. Pry the exhaust system back about 1/2" to gain workspace.
3. Remove the sheet metal screws that attach the inner fenderwells to the fender and frame of the truck and drop both inner fenderwells out.
4. Driver's Side: Working through the wheel well, loosen the EGR tube from the manifold. Remove the nuts attaching the manifold to the head and remove the manifold. Remove the exhaust studs from the head using a 1/4" drive ratchet and a 5mm socket.
5. Remove the oil dipstick (note the O-ring seal).
6. Remove the EGR fitting from the stock manifold to reuse on the new header.
7. Clean the head surface of any remaining gasket material or carbon deposits.

Installation of New Headers

1. Driver's Side: Slip the header into place from underneath the vehicle (some twisting and wiggling is required). Apply a small amount of anti-seize to the threads of the supplied header bolts. Attach the header using the supplied bolts, gaskets, and lock washers. Tighten evenly from the center out.
2. Loosen the EGR tube at the EGR valve to allow attachment to the fitting on the new header. Once both ends are in place, tighten the EGR tube. Re-install the dipstick.
3. Passenger's Side: Follow the same removal procedure as the driver's side. Install the new header through the wheel well, using anti-seize on the bolts and tightening evenly from the center out.
4. Apply a small amount of Sensor Safe High Temperature Silicone Sealant to the collector domes and reconnect the exhaust system using the provided hardware.

Post-Installation

• Re-connect the drive shaft on 4X4 vehicles.
• Re-install the inner wheel wells. On 4.6L models, it is recommended to remove the passenger side wheel well flap.
• Check that all wiring, fuel lines, transmission cooler lines, brake lines, and hoses are clear of the headers. Reroute or relocate components as necessary.
• Re-install the front wheels and torque to factory specs.
• Reconnect the battery.
• Start the engine, check for leaks, and test drive. Let the engine cool and then re-torque the header bolts.
• Periodically check and retighten the header bolts.

Parts List

• (1) Driver’s Side Header
• (1) Passenger’s Side Header
• (2) Header gaskets
• (4) 3/8-16 Collector Bolts
• (4) 3/8-16 Nuts
• (16) 8mm x 25mm Header Bolts
• (16) 8mm Lock washers
• (1) CARB EO Sticker