JBA 40-1502 - Manual

INSTALLATION INSTRUCTIONS
**Installation recommendation: **Installation recommendation: **Installation recommendation: **Installation recommendation:
JBA recommends in most cases that the vehicle be taken to a reputable exhaust shop.
G G G G
40-1502
1991-95 Jeep Wrangler 1991-95 Jeep Wrangler 1991-95 Jeep Wrangler 1991-95 Jeep Wrangler
A A A A
4.0L 4.0L 4.0L 4.0L L6 L6 L6 L6
T T T T OOLS RECOMMENDED: OOLS RECOMMENDED: OOLS RECOMMENDED: OOLS RECOMMENDED:
9/16''deep socket 9/16''deep socket 9/16''deep socket 9/16''deep socket
3/8î ratchet
3/8î ratchet 3/8î ratchet 3/8î ratchet
3/8'' Extension
3/8'' Extension 3/8'' Extension 3/8'' Extension
5/16''allen wrench
5/16''allen wrench 5/16''allen wrench 5/16''allen wrench
13mm socket
13mm socket 13mm socket 13mm socket D D D D
21mm socket 21mm socket 21mm socket 21mm socket
21mm combination wrench
21mm combination wrench 21mm combination wrench 21mm combination wrench
channel lock pliers
channel lock pliers channel lock pliers channel lock pliers
rubber mallet
rubber mallet rubber mallet rubber mallet
anti-seize
anti-seize anti-seize anti-seize
B
E
C
F
B
E
C
F
B
E
C
F
B
E
C
F
Part Part Part Part s List s List s List s List
A. A. A. A. Head pipe Head pipe Head pipe Head pipe 1 1 1 1
B. B. B. B. Muf Muf Muf Muffler fler fler fler 1 1 1 1
C. C. C. C. T T T Tail pipe w/tip ail pipe w/tip ail pipe w/tip ail pipe w/tip 1 1 1 1
D. D. D. D. 2-1/4î clamp 2-1/4î clamp 2-1/4î clamp 2-1/4î clamp 1 1 1 1
E. E. E. E. 2-1/2î clamp 2-1/2î clamp 2-1/2î clamp 2-1/2î clamp 1 1 1 1
F .F ...F F 2-1/2î clamp/hanger 2-1/2î clamp/hanger 2-1/2î clamp/hanger 2-1/2î clamp/hanger 1
G G G G .... Extra head pipe Extra head pipe Extra head pipe Extra head pipe 1
T T T T O O O O ST ST ST ST ART ART ART ART ::::
spray lubricant or penetrating oil spray lubricant or penetrating oil spray lubricant or penetrating oil spray lubricant or penetrating oil
reciprocating saw or hack saw
reciprocating saw or hack saw reciprocating saw or hack saw reciprocating saw or hack saw
p
p p pair of channel lock pliers 10î air of channel lock pliers 10î air of channel lock pliers 10î air of channel lock pliers 10î
2. Disconnect negative battery cable and 2. Disconnect negative battery cable and 2. Disconnect negative battery cable and 2. Disconnect negative battery cable and
allow vehicle exhaust to cool.
allow vehicle exhaust to cool. allow vehicle exhaust to cool. allow vehicle exhaust to cool.
1. Remove and inventory new Evol™ 1. Remove and inventory new Evol™ 1. Remove and inventory new Evol™ 1. Remove and inventory new Evol™
exhaust.
exhaust. exhaust. exhaust. 8. 8. 8. 8. Remove front muf Remove front muf Remove front muf Remove front muffler clamp using a fler clamp using a fler clamp using a fler clamp using a
15mm socket. 15mm socket. 15mm socket. 15mm socket.
14. 14. 14. 14.Inst Inst Inst Install muf all muf all muf all muffler (B) with of fler (B) with of fler (B) with of fler (B) with offset toward fset toward fset toward fset toward
rear and inward. rear and inward. rear and inward. rear and inward.
20. 20. 20. 20. Position muf Position muf Position muf Position muffler and inst fler and inst fler and inst fler and install 2 all 2 all 2 all 2 ''clamp ''clamp ''clamp ''clamp
(E) over front muf (E) over front muf (E) over front muf (E) over front muffler slip joint.T fler slip joint.T fler slip joint.T fler slip joint.Tighten ighten ighten ighten
completely using a 9/16'' deep wall sock- completely using a 9/16'' deep wall sock- completely using a 9/16'' deep wall sock- completely using a 9/16'' deep wall sock­
et.
et. et. et. NOTE: NOTE: NOTE: NOTE: USE USE USE USE ANTI SEIZE ON ANTI SEIZE ON ANTI SEIZE ON ANTI SEIZE ON
THREADS OF CLAMP THREADS OF CLAMP THREADS OF CLAMP THREADS OF CLAMP . See notes #3 . See notes #3 . See notes #3 . See notes #3
9. S 9. S 9. S 9. Spray lube on two rear muf pray lube on two rear muf pray lube on two rear muf pray lube on two rear muffler hanger fler hanger fler hanger fler hanger
rod rubber grommet rod rubber grommet rod rubber grommet rod rubber grommets. s. s. s. 15. Inst 15. Inst 15. Inst 15. Install rear muf all rear muf all rear muf all rear muffler clamp/hanger (F) fler clamp/hanger (F) fler clamp/hanger (F) fler clamp/hanger (F)
into lower holes in rubber grommet into lower holes in rubber grommet into lower holes in rubber grommet into lower holes in rubber grommets, with s, with s, with s, with
rods pointing toward p rods pointing toward p rods pointing toward p rods pointing toward passenger side. assenger side. assenger side. assenger side. 21. Reinst 21. Reinst 21. Reinst 21. Reinstall p all p all p all pan bar over rear axle. an bar over rear axle. an bar over rear axle. an bar over rear axle.
Check for proper clearance on t Check for proper clearance on t Check for proper clearance on t Check for proper clearance on tail pipe. ail pipe. ail pipe. ail pipe.
3. With vehicle raised and properly sup- 3. With vehicle raised and properly sup- 3. With vehicle raised and properly sup- 3. With vehicle raised and properly sup­
ported, remove p
ported, remove p ported, remove p ported, remove pan bar over rear axle by an bar over rear axle by an bar over rear axle by an bar over rear axle by
removing two bolt removing two bolt removing two bolt removing two bolts using a 21mm socket s using a 21mm socket s using a 21mm socket s using a 21mm socket
or combination wrench and 5/16'' allen- or combination wrench and 5/16'' allen- or combination wrench and 5/16'' allen- or combination wrench and 5/16'' allen­
wrench.
wrench. wrench. wrench.
4. 4. 4. 4. Using a reciprocating saw Using a reciprocating saw Using a reciprocating saw Using a reciprocating saw, cut t , cut t , cut t , cut tail pipe ail pipe ail pipe ail pipe
of of of off 4''behind rear muf f 4''behind rear muf f 4''behind rear muf f 4''behind rear muffler hanger fler hanger fler hanger fler hanger....
See notes #1 See notes #1 See notes #1 See notes #1
1 1 1 11. 1. 1. 1. Using some form of heat and force Using some form of heat and force Using some form of heat and force Using some form of heat and force
remove muf remove muf remove muf remove muffler assembly without damag- fler assembly without damag- fler assembly without damag- fler assembly without damag­
ing stock cat ing stock cat ing stock cat ing stock catalytic converter pipe. alytic converter pipe. alytic converter pipe. alytic converter pipe.
10. 10. 10. 10. Support muf Support muf Support muf Support muffler and remove two rear fler and remove two rear fler and remove two rear fler and remove two rear
muf muf muf muffler hangers from rubber grommet fler hangers from rubber grommet fler hangers from rubber grommet fler hangers from rubber grommets s s s
using channel lock pliers. using channel lock pliers. using channel lock pliers. using channel lock pliers.
16. Position rear muf 16. Position rear muf 16. Position rear muf 16. Position rear muffler clamp/hanger fler clamp/hanger fler clamp/hanger fler clamp/hanger
(F),over rear muf (F),over rear muf (F),over rear muf (F),over rear muf fler slip joint and hand fler slip joint and hand fler slip joint and hand fler slip joint and hand
tighten only at this time. tighten only at this time. tighten only at this time. tighten only at this time.
17. 17. 17. 17. Inst Inst Inst Install factory rear t all factory rear t all factory rear t all factory rear tail pipe rubber ail pipe rubber ail pipe rubber ail pipe rubber
grommet on rear t grommet on rear t grommet on rear t grommet on rear tail pipe hanger rod. ail pipe hanger rod. ail pipe hanger rod. ail pipe hanger rod.
23. Check exhaust kit for proper clear- 23. Check exhaust kit for proper clear- 23. Check exhaust kit for proper clear- 23. Check exhaust kit for proper clear­
ances, and t
ances, and t ances, and t ances, and tack weld all slip joint ack weld all slip joint ack weld all slip joint ack weld all slip joints in s in s in s in
three spot three spot three spot three spots. s. s. s.
22. Position t 22. Position t 22. Position t 22. Position tail pipe, checking chrome tip ail pipe, checking chrome tip ail pipe, checking chrome tip ail pipe, checking chrome tip
for clearance, and tighten clamp/hanger for clearance, and tighten clamp/hanger for clearance, and tighten clamp/hanger for clearance, and tighten clamp/hanger
(F) completely using a 9/16'' deep wall
(F) completely using a 9/16'' deep wall (F) completely using a 9/16'' deep wall (F) completely using a 9/16'' deep wall
socket.
socket. socket. socket. NOTE: NOTE: NOTE: NOTE: USE USE USE USE ANTI SEIZE ON ANTI SEIZE ON ANTI SEIZE ON ANTI SEIZE ON
THREADS OF CLAMP THREADS OF CLAMP THREADS OF CLAMP THREADS OF CLAMP . See notes #3 . See notes #3 . See notes #3 . See notes #3
5. 5. 5. 5. Remove rear t Remove rear t Remove rear t Remove rear tail pipe hanger using a ail pipe hanger using a ail pipe hanger using a ail pipe hanger using a
13mm socket and extension. 13mm socket and extension. 13mm socket and extension. 13mm socket and extension.
12. Inst 12. Inst 12. Inst 12. Install Evol™ head pipe (A), aligning all Evol™ head pipe (A), aligning all Evol™ head pipe (A), aligning all Evol™ head pipe (A), aligning
notch with locating pin. Note: you may notch with locating pin. Note: you may notch with locating pin. Note: you may notch with locating pin. Note: you may
have to t
have to t have to t have to tap on with rubber mallet. ap on with rubber mallet. ap on with rubber mallet. ap on with rubber mallet.
See See See See notes #2 notes #2 notes #2 notes #2
18. 18. 18. 18.Inst Inst Inst Install t all t all t all tail pipe from rear of vehicle. ail pipe from rear of vehicle. ail pipe from rear of vehicle. ail pipe from rear of vehicle.
Place rubber grommet in holder and slip Place rubber grommet in holder and slip Place rubber grommet in holder and slip Place rubber grommet in holder and slip
ttttail pipe into rear muf
ail pipe into rear muf ail pipe into rear muf ail pipe into rear muffler slip joint 2''. fler slip joint 2''. fler slip joint 2''. fler slip joint 2''.
24. Using a sof 24. Using a sof 24. Using a sof 24. Using a soft cloth, remove all print t cloth, remove all print t cloth, remove all print t cloth, remove all prints s s s
from turnout tip. from turnout tip. from turnout tip. from turnout tip.
25. Lower vehicle and reatt
25. Lower vehicle and reatt 25. Lower vehicle and reatt 25. Lower vehicle and reattach the ach the ach the ach the
negative battery cable. negative battery cable. negative battery cable. negative battery cable.
NOTES: NOTES: NOTES: NOTES:
1. 1. 1. 1. If vehicle is lif If vehicle is lif If vehicle is lif If vehicle is lifted with proper vehicle ted with proper vehicle ted with proper vehicle ted with proper vehicle
lif lif lif lift, step #4 can be eliminated. t, step #4 can be eliminated. t, step #4 can be eliminated. t, step #4 can be eliminated. The muf- The muf- The muf- The muf­
fler assembly can be removed in one fler assembly can be removed in one fler assembly can be removed in one fler assembly can be removed in one
piece by removing right rear shock, and
piece by removing right rear shock, and piece by removing right rear shock, and piece by removing right rear shock, and
raising right rear frame rail.
raising right rear frame rail. raising right rear frame rail. raising right rear frame rail.
2.
2. 2. 2. Due to the possibility of stock cat Due to the possibility of stock cat Due to the possibility of stock cat Due to the possibility of stock catalytic alytic alytic alytic
converter being changed or altered from converter being changed or altered from converter being changed or altered from converter being changed or altered from
6. 6. 6. 6. Remove t Remove t Remove t Remove tail pipe from rear of vehicle. ail pipe from rear of vehicle. ail pipe from rear of vehicle. ail pipe from rear of vehicle.
7. 7. 7. 7. Remove rubber grommet from t Remove rubber grommet from t Remove rubber grommet from t Remove rubber grommet from tail pipe ail pipe ail pipe ail pipe
hanger rod and save, as it will be reused. hanger rod and save, as it will be reused. hanger rod and save, as it will be reused. hanger rod and save, as it will be reused.
13. 13. 13. 13.Inst Inst Inst Install and position 2 º''clamp (D), all and position 2 º''clamp (D), all and position 2 º''clamp (D), all and position 2 º''clamp (D),
over head pipe (A) slip joint and tighten over head pipe (A) slip joint and tighten over head pipe (A) slip joint and tighten over head pipe (A) slip joint and tighten
completely using a 9/16'' deep wall sock-
completely using a 9/16'' deep wall sock- completely using a 9/16'' deep wall sock- completely using a 9/16'' deep wall sock­
et.
et. et. et. NOTE: NOTE: NOTE: NOTE: USE USE USE USE ANTI SEIZE ON ANTI SEIZE ON ANTI SEIZE ON ANTI SEIZE ON
THREADS OF CLAMP THREADS OF CLAMP THREADS OF CLAMP THREADS OF CLAMP . See notes #3 . See notes #3 . See notes #3 . See notes #3
19. 19. 19. 19. Reassemble rear t Reassemble rear t Reassemble rear t Reassemble rear tail pipe hanger ail pipe hanger ail pipe hanger ail pipe hanger
assembly assembly assembly assembly, and tighten using a 13mm , and tighten using a 13mm , and tighten using a 13mm , and tighten using a 13mm
socket. socket. socket. socket.
stock, JBA has supplied an extra head stock, JBA has supplied an extra head stock, JBA has supplied an extra head stock, JBA has supplied an extra head
pipe with a longer length for customer to
pipe with a longer length for customer to pipe with a longer length for customer to pipe with a longer length for customer to
cut at his discretion for a custom fit. First
cut at his discretion for a custom fit. First cut at his discretion for a custom fit. First cut at his discretion for a custom fit. First
you must inst
you must inst you must inst you must install Evol™ all Evol™ all Evol™ all Evol™ tail pipe (C), rear tail pipe (C), rear tail pipe (C), rear tail pipe (C), rear
muf muf muf muffler clamp/hanger (F), and muf fler clamp/hanger (F), and muf fler clamp/hanger (F), and muf fler clamp/hanger (F), and muffler (B) fler (B) fler (B) fler (B)
and position for proper clearance, to and position for proper clearance, to and position for proper clearance, to and position for proper clearance, to
determine where to cut extra head pipe
determine where to cut extra head pipe determine where to cut extra head pipe determine where to cut extra head pipe
supplied.
supplied. supplied. supplied.
3.
3. 3. 3. If anti seize is not used on threads of If anti seize is not used on threads of If anti seize is not used on threads of If anti seize is not used on threads of
clamp clamp clamp clamps before tightening, the nut's will s before tightening, the nut's will s before tightening, the nut's will s before tightening, the nut's will
gall, and clamp rod will break. gall, and clamp rod will break. gall, and clamp rod will break. gall, and clamp rod will break.
aking the truck to a muffler shop and having all slip connections t aking the truck to a muffler shop and having all slip connections t aking the truck to a muffler shop and having all slip connections t aking the truck to a muffler shop and having all slip connections t ack welded. ack welded. ack welded. ack welded. 17227 17227 17227 17227