Edelbrock 651107 Automobile Parts User Manual

Edelbrock Headers

For 1999-2003 Ford F-150, 1999-2002 Expedition,

1999-2002 Ford F-250 Excluding Super Duty,

5.4L V8 2WD & 4WD without Air Ride Suspension

Catalog #65632 & #65633

INSTALLATION INSTRUCTIONS

Please study these instructions carefully before installing your new Headers. If you have any questions or problems, please contact our Technical Hotline at : 1-800-416-8628 from 7 am – 5 pm, Monday through Friday, Pacific Standard Time or e-mail us at [email protected]. Please complete and mail your warranty card.

DESCRIPTION: These components are designed to improve the exhaust efficiency of the Ford 5.4 Litre V8 engine. This system does not require welding for installation and retains all O.E.M. emissions equipment. These Edelbrock headers are street legal in all 50 states. These systems should be installed by an experienced/qualified mechanic.

Suggested tools needed for installation: This vehicle has some metric fasteners.

❑ 3/8" ratchet socket set with extensions and universal 13mm and 15mm swivel sockets

❑ Combination set of open-end wrenches

❑ Jackstands, screwdrivers, pliers, crescent wrench, etc.

❑ Liquid penetrant, (GM #1052627) anti-seize compound (GM #5613695)

❑ 13mm open end wrench (stubby)

❑ 1/4" ratchet socket set with extensions and swivel

SPECIAL NOTICE: This Edelbrock part has received an Executive Order number (E.O. #) from the California Air Resources Board

(C.A.R.B.) making it legal for street use on pollution-controlled motor vehicles in all 50 states. To assist you with emissions equipment certification, we have included a silver fan shroud decal to help testing personnel verify that this part is a legal replacement part on the vehicle for which it is cataloged. The adhesive-backed decal should be affixed to your fan shroud next to the existing emission and engine specification decal. Do not cover your original equipment specification decal with the Edelbrock fan shroud decal.

WARNING: The use of “Thermal Wrap” or any aftermarket coating process will void the warranty on your Headers. Those products can cause excessive heat and moisture build up resulting in corrosion and early failure of the system.

INSTALLATION INSTRUCTIONS

DISASSEMBLY:

1. Disconnect negative battery cable.

2. Raise truck and disconnect exhaust pipes from both left and right manifolds.

3. Removal of front tires will make installation much easier.

4. Remove both left and right plastic fender wells.

5. Disconnect and remove starter from vehicle.

LEFT SIDE

1. Disconnect and remove EGR tube from vehicle.

2. Remove nuts and studs from manifold.

3. Remove stock manifold and gasket from vehicle through wheel well.

4. Disconnect dipstick. (Note: Dipstick must be placed between primary pipes 2 & 3 before bolting on header).

5. Install port flange gasket and one 8mm bolt, lock washer, and flat washer at rear most bolt hole. Leave bolt loose enough to accept header.

6. Place header into position through wheel well. With dipstick and header in place, start all bolts and washers, then tighten evenly from center out.

7. Install the new EGR tube (supplied with system).

©2005 Edelbrock Corporation

Catalog #65632 & #65633 Page 1 of 2

Brochure #63-0401

Rev. 5/05 - DA/mc

RIGHT SIDE

1. Remove bracket from air conditioning lines that mounts to firewall to allow air lines to move around freely (Ford Expedition Only).

2. Remove nuts and studs, then remove stock manifold and gasket from vehicle through wheel well.

3. Install port flange gasket and one 8mm bolt, lock washer, and flat washer at rear most bolt hole.

Leave bolt loose enough to accept header.

4. Place header into position through wheel well. Start all bolts and washers, then tighten.

5. Reconnect air conditioning lines to firewall.

FINAL ASSEMBLY

1. Bolt on and re-connect starter to vehicle.

2. With collector donuts on headers, re-connect exhaust pipes to headers using supplied bolts and lock washers.

3. Re-connect battery.

4. Start vehicle and bring up to normal temperature.

Check for possible leaks.

5. Turn engine off and let cool. Re-tighten all bolts.

6. Re-install fender wells.

7. Re-install front tires if removed. Be sure to torque lug nuts to factory specifications.

1

2

2

Qty.

1

1

Part #

25-9257

25-9258

25-9666

-

-

Part #65632 (Ceramic-Coated) - Parts List

Description

Manifold left side

Manifold right side

Qty.

16

16

Part #

-

-

Description

8mm x 1.25” x 30mm Header bolts

5/16” Lock washers

EGR tube assembly 16 5/16” I.D x 1/8” thick Black

Port gaskets hardened washers

Donut gaskets - 2 1/2” diameter 4 3/8” - 16 x 2” Hex bolts

4 3/8” Lock washers

1

2

2

Qty.

1

1

Part #

25-9237

25-9238

25-9666

-

-

Part #65633 (Ti-Tech Coated) - Parts List

Description

Manifold left side

Manifold right side

Qty.

16

16

Part #

-

-

Description

8mm x 1.25” x 30mm Header bolts

5/16” Lock washers

EGR tube assembly 16 5/16” I.D x 1/8” thick Black

Port gaskets hardened washers

Donut gaskets - 2 1/2” diameter 4 3/8” - 16 x 2” Hex bolts

4 3/8” Lock washers

©2005 Edelbrock Corporation

Catalog #65632 & #65633

Edelbrock Corporation

2700 California Street

Torrance, CA 90503

Toll-Free Tech Line: 1-800-416-8628

Tech E-Mail: [email protected]

Page 2 of 2

Brochure #63-0401

Rev. 5/05 - DA/mc