JBA 1938S 1992-95 Dodge Dakota and Ram 1500 3.9 V6 Cat4Ward Headers Instruction Manual

JBA 1938S 1992-95 Dodge Dakota and Ram 1500 3.9 V6 Cat4Ward Headers 

PERTRONIX PERFORMANCE B NOS EMISSIONS CODES ‘This product has been granted a California Air Resources Board (CARP) Executive Order (EC Number) Exemptim It is SO State Legal when installed on the Specified vehicle per the Manufacturer’s Current Application Guide, the CARE( EEC and Installation Instructions, 1111130001

WARNING:
This product can expose you to chemica ls including Lead, Nickel, Cadmium and Chromium which are known to the State of Ca liforn ia to cause cancer and birth defects or other reproductive harm. For more information go to www.P65Warnings.ca.gov

PLEASE READ BEFORE PROCEEDING

PerTronix©thanks you for choosing a JBA Performance Exhaust Product. To realize the potential of JBA’s engineering and excellent fit, Please Read and Understand these instructions completely prior to starting the installation.
Check that you received all the parts listed on the parts list, if you have any concerns, please contact PerTronix before continuing. Headers will have the part number stamped in the flange. Work Smart – Work Safe! Most Header and Exhaust Installation are best performed on a lift. If a lift is not available, raise the vehicle and support on quality Jack Stands on level ground. Do not rely on a jack!
We use sealing beads on all our headers. The raised bead creates a better seal virtually eliminating leaks if installed properly. It is important to install all header bolts lightly snug and then tighten to factory torque specs starting in the center and working outward.
Before starting, allow the vehicle to cool, disconnect the battery, and spray a penetrating oil on all hardware and fittings that will need to be removed . Once you remove your manifold, clean the sealing surface on the head of any old gasket debris or carbon build up.

1. From underneath the vehicle disconnect the Y-pipe from the exhaust manifold.
2. Driver’s Side. Unbolt the two outer bolts and the center two nuts that attach the manifold to the head. Put both nuts on one of the center studs and remove the stud by tightening the inner nut against the outer one. Repeat this process to remove the other stud.
3. Clean the sealing surface on the cylinder head. Apply a bead of high temp RTV to the dome on the headers in order to avoid problems later due to lack of space in the installation.
4. Holding the header in place, slide the new gasket between the motor and the header. Due to limited clearance, slip the center two bolts and lock washers in place before placing the header against the head and start these two first. Install the other two header bolts with washers. Be sure to tighten bolts evenly from the center out.
5. Passenger Side – On 1992 -1995 models remove the bolts attaching the EGR tube to the exhaust manifold. Once the bolts have been removed, slightly loosen the tube at the EGR valve (located on the back of the intake manifold) Do not Remove Tube. Repeat the process from the driver’s side for removing the manifold and studs.
6. Clean the sealing surface on the cylinder head. Apply a bead of high temp RTV to dome on the headers in order to avoid problems due to lack of space later on in the installation.
7. *On 1997-99 Models it may be necessary to remove the coil in order to install the new header. Holding the header in place, slide the new gasket between the motor and the header. Due to limited clearance, slip the center two bolts and lock washers in place before placing the header against the head and start these two first. Install the other two header bolts with washers. Tighten the bolts evenly from the center out. 92-95 vehicles install the new EGR gasket on the fitting of the EGR tube and retighten the air tube using the hardware provided.
8. Due to the design and materials used on the factory y-pipe, it is common to have the y-pipe assembly distort from its original shape. This distortion is caused by the repeated heating and cooling of the assembly, which works as a stress relieving process. Because of this, the y-pipe may not line up perfectly with the header collector. To make reconnecting the assembly easier, begin by securely connecting one side (whichever is easiest) and then pulling the y-pipe into place. Bolt the exhaust to the headers using the supplied hardware.
9. Check to make sure there is adequate clearance on plug wires, battery cables, wire looms, brake lines, etc. Re-connect battery cables.
10. Start the engine and let it warm up. Check for leaks. Shut engine off and let it cool down. Check to make sure all fasteners are tight.
11. All tubular headers require maintenance including periodically checking and retightening of the header bolts.

Parts List:

1) Driver’s Side Header Assembly
(2) Header gaskets (Header to Head flange)
(1) Passenger’s Side Header Assembly
(8) 5/16″ x 1 “header bolts &lock washers
(1) EGR Gasket (1938S)
(4) 3/8 “x 2 1/2 “Collector Bolts, Nuts &Washers.
(2) 1/4 “x 1 1/4 “Air Fitting Bolts, Washers &Lock Nuts.(1938S)
(1) CARB EO Sticker

WARNING

This label is required to aid in passing the California smog check program. This label must be installed in an underhood location that is readily visible.

JBA LIMTED WARRANTY

All 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 or product failure resulting from collision. improper installation. off-road use, road hazards. the use of exhaust insulating wrap or like products or rust occurring after installation, is not covered by the warranty. The warranty extends only to the original purchaser_ Should a part become defective it should be returned to the original selling retailer and must be accompanied with the sales receipt If there is no retailer in your area. call the factory for a return authorization and return your part prepaid to the factory for inspection_ PerTronix reserves the rights to replace or repair the alleged defective part and return the part freight collect.

Documents / Resources

JBA 1938S 1992-95 Dodge Dakota and Ram 1500 3.9 V6 Cat4Ward Headers [pdf] Instruction Manual 1938S, 1992-95 Dodge Dakota and Ram 1500 3.9 V6 Cat4Ward Headers, 1938S 1992-95 Dodge Dakota and Ram 1500 3.9 V6 Cat4Ward Headers, Dodge Dakota and Ram 1500 3.9 V6 Cat4Ward Headers, Dodge Dakota and Ram 1500 3.9 V6 Cat4Ward Headers, 1939S

References

• User Manual