JBA 40-1501 - Manual

INSTALLATION INSTRUCTIONS
* Installation Recommendation: JBA recommends in most cases that the vehicle be taken to a reputable exhaust shop.
40-1501
2000-2006 Jeep Wrangler 2.5/4.0L TJ 4wd
PARTS LIST:
RECOMMENDED TOOLS:
A. Tail pipe 1
pry bar
B. Muffler 1
ratchet
C. Intermediate pipe 1
15mm deep socket
D. Rear muffler clamp hanger 1
channel lock pliers
E. U-bolt clamp 1
anti-seize
spray lubricant or penetrating oil
A.
B.
C.
D.
E.
1. Remove and inventory JBA exhaust.
TO START:
2. Disconnect negative battery cable
and allow vehicle exhaust to cool.
3. Spray fasteners with penetrating oil.
7. Install new intermediate pipe
with hardware provided.
14. Tack weld all slip connections in
three spots.
15. Lower the vehicle and reattach th
negative battery cable.
NOTES:
1) All exhaust systems will expand ab
1" rearward when exhaust temperat
start to rise.
2) Use Anti-seize on threads of clamp
ures
e
out
s.
4. Separate muffler and tailpipe by
cutting tailpipe behind muffler with
reciprocating saw or similar.
10. Slip tailpipe over axle and E-brake
cable. Inser into rear of muffler.v
5. Spray lubricant on rubber isolators,
slip tailpipe hangers out of rubber
isolators, remove tailpipe from
vehicle.
8. Slip a U-bolt clamp onto the I-pipe.
Slip muffler onto I-pipe with offset
towards the front, and the muffler
extending towards the driveshaft.
Align muffler to be flat.
9. Slip rear muffler clamp hanger
into rubber isolator. Position onto
muffler, snug lightly.
11. Insert tailpipe hanger into rubber
isolator.
12. Align tailpipe to clear shock, fuel
tank, and suspension
6. Unbolt flange in front of muffler.
Remove muffler from vehicle
13. Secure all fasteners and clamps.
Muffler slip joints should be tack
welded.
Rev 2.19.06