JBA 40-1508 - Manual

INSTALLATION INSTRUCTIONS
**Inst **Inst **Inst **Inst allation recommendation: allation recommendation: allation recommendation: allation recommendation:
JBA recommends in most cases that the vehicle be taken to a reputable exhaust shop. JBA recommends in most cases that the vehicle be taken to a reputable exhaust shop. JBA recommends in most cases that the vehicle be taken to a reputable exhaust shop. JBA recommends in most cases that the vehicle be taken to a reputable exhaust shop.
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, 24" , 24" , 24" , 24" 1 1 1 1
1998-00 Dodge Ram 1500/2500 1998-00 Dodge Ram 1500/2500 1998-00 Dodge Ram 1500/2500 1998-00 Dodge Ram 1500/2500 All All All All
C. C. C. C. T T T Tail pipe ail pipe ail pipe ail pipe 1 1 1 1
T OOLS RECOMMENDED:
9/16 deep socket
ratchet
10mm wrench
15mm deep socket
prybar
rubber mallet
spray lubricant or penetrating oil
anti-seize
reciprocating saw or hack saw
pair of channel lock pliers
T OOLS RECOMMENDED:
9/16 deep socket
ratchet
10mm wrench
15mm deep socket
prybar
rubber mallet
spray lubricant or penetrating oil
anti-seize
reciprocating saw or hack saw
pair of channel lock pliers
T OOLS RECOMMENDED:
9/16 deep socket
ratchet
10mm wrench
15mm deep socket
prybar
rubber mallet
spray lubricant or penetrating oil
anti-seize
reciprocating saw or hack saw
pair of channel lock pliers
T OOLS RECOMMENDED:
9/16 deep socket
ratchet
10mm wrench
15mm deep socket
prybar
rubber mallet
spray lubricant or penetrating oil
anti-seize
reciprocating saw or hack saw
pair of channel lock pliers
D. Turn out 1
E. 2-1/2" clamp 1
F. 3" clamp 1
G. 3" clamp 1
H. Tail pipe clamp/hanger 1
D. Turn out 1
E. 2-1/2" clamp 1
F. 3" clamp 1
G. 3" clamp 1
H. Tail pipe clamp/hanger 1
D. Turn out 1
E. 2-1/2" clamp 1
F. 3" clamp 1
G. 3" clamp 1
H. Tail pipe clamp/hanger 1
D. Turn out 1
E. 2-1/2" clamp 1
F. 3" clamp 1
G. 3" clamp 1
H. Tail pipe clamp/hanger 1
H
D
B
G
F
E
A C
H
D
B
G
F
E
A C
H
D
B
G
F
E
A C
H
D
B
G
F
E
A C
40-1508
T T T T O O O O ST ST ST ST ART ART ART ART ::::
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 JBA 1. Remove and inventory new JBA 1. Remove and inventory new JBA 1. Remove and inventory new JBA
exhaust.
exhaust. exhaust. exhaust.
13. Using the 3" clamp (F), tighten clamp 13. Using the 3" clamp (F), tighten clamp 13. Using the 3" clamp (F), tighten clamp 13. Using the 3" clamp (F), tighten clamp
completely using 9/16"deep wall socket.
completely using 9/16"deep wall socket. completely using 9/16"deep wall socket. completely using 9/16"deep wall socket.
7. Remove t 7. Remove t 7. Remove t 7. 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.
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, using a reciprocating saw or hack
ported, using a reciprocating saw or hack ported, using a reciprocating saw or hack ported, using a reciprocating saw or hack
saw
saw saw saw, cut t , cut t , cut t , cut tail pipe approximately 1" behind ail pipe approximately 1" behind ail pipe approximately 1" behind ail pipe approximately 1" behind
rear muf rear muf rear muf rear muffler clamp and in front of t fler clamp and in front of t fler clamp and in front of t fler clamp and in front of tail pipe ail pipe ail pipe ail pipe
hanger hanger hanger hanger....
4. S 4. S 4. S 4. Spray lubricant on lower holes of front pray lubricant on lower holes of front pray lubricant on lower holes of front pray lubricant on lower holes of front
and rear t and rear t and rear t and rear tail pipe hanger rubber grommet ail pipe hanger rubber grommet ail pipe hanger rubber grommet ail pipe hanger rubber grommets. s. s. s.
10. Using some form of heat and force, 10. Using some form of heat and force, 10. Using some form of heat and force, 10. Using some form of heat and force,
disengage and remove muf
disengage and remove muf disengage and remove muf disengage and remove muffler without fler without fler without fler without
damaging head pipe. damaging head pipe. damaging head pipe. damaging head pipe.
1 1 1 11. 1. 1. 1. Align notch with locating pin and inst Align notch with locating pin and inst Align notch with locating pin and inst Align notch with locating pin and install all all all
head pipe (A) using the 2-1/2" clamp (E). head pipe (A) using the 2-1/2" clamp (E). head pipe (A) using the 2-1/2" clamp (E). head pipe (A) using the 2-1/2" clamp (E).
T
T T Tighten completely with 9/16" deep wall ighten completely with 9/16" deep wall ighten completely with 9/16" deep wall ighten completely with 9/16" deep wall
8. S 8. S 8. S 8. Spray penetrating oil on threads of front pray penetrating oil on threads of front pray penetrating oil on threads of front pray penetrating oil on threads of front
muf muf muf muffler clamp. fler clamp. fler clamp. fler clamp.
9. Using a 15mm socket, remove front 9. Using a 15mm socket, remove front 9. Using a 15mm socket, remove front 9. Using a 15mm socket, remove front
muf
muf muf muffler clamp. fler clamp. fler clamp. fler clamp.
14. Inst 14. Inst 14. Inst 14. Install t all t all t all tail pipe (C) from rear of vehi- ail pipe (C) from rear of vehi- ail pipe (C) from rear of vehi- ail pipe (C) from rear of vehi­
cle with double hanger towards muf cle with double hanger towards muf cle with double hanger towards muf cle with double hanger towards muffler fler fler fler....
15. Inst 15. Inst 15. Inst 15. Install front two hangers on t all front two hangers on t all front two hangers on t all front two hangers on tail pipe ail pipe ail pipe ail pipe
(C) into lower holes of rubber grommet. (C) into lower holes of rubber grommet. (C) into lower holes of rubber grommet. (C) into lower holes of rubber grommet.
20. 20. 20. 20. Af Af Af After inst ter inst ter inst ter installation, it is recommended allation, it is recommended allation, it is recommended allation, it is recommended
that all clamp that all clamp that all clamp that all clamps be retightened and joint s be retightened and joint s be retightened and joint s be retightened and joints s s s
ttttack welded in 3 spot ack welded in 3 spot ack welded in 3 spot ack welded in 3 spots. s. s. s.
21. Using a sof 21. Using a sof 21. Using a sof 21. 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.
22. Lower vehicle and reatt 22. Lower vehicle and reatt 22. Lower vehicle and reatt 22. Lower vehicle and reattach the nega- ach the nega- ach the nega- ach the nega­
tive battery cable. tive battery cable. tive battery cable. tive battery cable.
NOTES: NOTES: NOTES: NOTES:
1) It may be necessary to loosen and 1) It may be necessary to loosen and 1) It may be necessary to loosen and 1) It may be necessary to loosen and
realign the sp
realign the sp realign the sp realign the spare tire for proper clear- are tire for proper clear- are tire for proper clear- are tire for proper clear­
ance. ance. ance. ance.
2) 2) 2) 2) All exhaust systems will exp All exhaust systems will exp All exhaust systems will exp All exhaust systems will expand about and about and about and about
1î rearward when exhaust temperature 1î rearward when exhaust temperature 1î rearward when exhaust temperature 1î rearward when exhaust temperature
st
st st start to rise. art to rise. art to rise. art to rise.
18. Inst 18. Inst 18. Inst 18. Install turn out (D) to end of t all turn out (D) to end of t all turn out (D) to end of t all turn out (D) to end of tail pipe ail pipe ail pipe ail pipe
(C) rot (C) rot (C) rot (C) rotate to desired position approx. 1" ate to desired position approx. 1" ate to desired position approx. 1" ate to desired position approx. 1"
from body from body from body from body....
19. 19. 19. 19. T T T Tighten clamp/hanger (H) completely ighten clamp/hanger (H) completely ighten clamp/hanger (H) completely ighten clamp/hanger (H) completely
using 9/16" deep wall socket. using 9/16" deep wall socket. using 9/16" deep wall socket. using 9/16" deep wall socket.
Note: Note: Note: Note: Use anti-seize on threads. Use anti-seize on threads. Use anti-seize on threads. Use anti-seize on threads.
socket. socket. socket. socket. Note: Note: Note: Note: Use anti-seize on threads. Use anti-seize on threads. Use anti-seize on threads. Use anti-seize on threads.
3) Use 3) Use 3) Use 3) Use Anti-seize on threads of clamp Anti-seize on threads of clamp Anti-seize on threads of clamp Anti-seize on threads of clamps. s. s. s.
5. Using a p 5. Using a p 5. Using a p 5. Using a pair of channel lock pliers, air of channel lock pliers, air of channel lock pliers, air of channel lock pliers,
remove hanger rods from bottom holes of remove hanger rods from bottom holes of remove hanger rods from bottom holes of remove hanger rods from bottom holes of
two rear t
two rear t two rear t two rear tail pipe rubber grommet ail pipe rubber grommet ail pipe rubber grommet ail pipe rubber grommets. s. s. s.
16. Inst 16. Inst 16. Inst 16. Install rear t all rear t all rear t all rear tail pipe hanger into rubber ail pipe hanger into rubber ail pipe hanger into rubber ail pipe hanger into rubber
grommet. grommet. grommet. grommet. Align t Align t Align t Align tail pipe and tighten 3" ail pipe and tighten 3" ail pipe and tighten 3" ail pipe and tighten 3"
clamp (G) completely clamp (G) completely clamp (G) completely clamp (G) completely.... Note: Note: Note: Note: Use anti- Use anti- Use anti- Use anti­
seize on threads. seize on threads. seize on threads. seize on threads.
6. Using a p 6. Using a p 6. Using a p 6. Using a pair of channel lock pliers, air of channel lock pliers, air of channel lock pliers, air of channel lock pliers,
remove front t remove front t remove front t remove front tail pipe hanger rod from ail pipe hanger rod from ail pipe hanger rod from ail pipe hanger rod from
bottom hole in rubber grommet. bottom hole in rubber grommet. bottom hole in rubber grommet. bottom hole in rubber grommet.
12. With JBA logo facing rear of vehicle, 12. With JBA logo facing rear of vehicle, 12. With JBA logo facing rear of vehicle, 12. With JBA logo facing rear of vehicle,
inst
inst inst install muf all muf all muf all muffler (B) over head pipe (A) mak- fler (B) over head pipe (A) mak- fler (B) over head pipe (A) mak- fler (B) over head pipe (A) mak­
ing sure muf ing sure muf ing sure muf ing sure muffler bottoms out on slip joint. fler bottoms out on slip joint. fler bottoms out on slip joint. fler bottoms out on slip joint.
17. Inst 17. Inst 17. Inst 17. Install turn out clamp/hanger (H) all turn out clamp/hanger (H) all turn out clamp/hanger (H) all turn out clamp/hanger (H)
over end of t over end of t over end of t over end of tail pipe (C) and into rubber ail pipe (C) and into rubber ail pipe (C) and into rubber ail pipe (C) and into rubber
grommet. grommet. grommet. grommet.
17039a 17039a 17039a 17039a
W W W We e e e recommend taking the truck to a muffler shop and having all slip connections tack welded recommend taking the truck to a muffler shop and having all slip connections tack welded recommend taking the truck to a muffler shop and having all slip connections tack welded recommend taking the truck to a muffler shop and having all slip connections tack welded
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