JBA 40-1520 - 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.
Part Part Part Part s List s List s List s List
40-1520
A. A. A. A. Head pipe Head pipe Head pipe Head pipe 1 1 1 1 2002 Dodge Ram quad cab/std. bed 4.7/5.9L V-8
B. B. B. B. Muf Muf Muf Muffler fler fler fler, 24" 1 1 1 1
C. C. C. C. T T T Tail pipe ail pipe ail pipe ail pipe 1 1 1 1 40-1521
D. D. D. D. T T T Turn out urn out urn out urn out 1 1 1 1
E. E. E. E. G G G G 2-1/2" clamp 1 1 1 1 2002 Dodge Ram std. cab/short bed 4.7/5.9L V-8
F. 3" clamp hanger
G. 3" clamp hanger
H. 3" clamp F.
G.
H. F.
G.
H. F.
G.
H.
H D
E
A A A B
F
E E E
A (For 1520)
C
1 1 1 1
T T T T OOLS RECOMMENDED: OOLS RECOMMENDED: OOLS RECOMMENDED: OOLS RECOMMENDED: 1 1 1 1
1
1 1 1
9/16 deep socket 9/16 deep socket 9/16 deep socket 9/16 deep socket
ratchet
ratchet ratchet ratchet
10mm wrench
10mm wrench 10mm wrench 10mm wrench
15mm deep socket
15mm deep socket 15mm deep socket 15mm deep socket
prybar
prybar prybar prybar
rubber mallet
rubber mallet rubber mallet rubber mallet
spray lubricant or penetrating oil
spray lubricant or penetrating oil spray lubricant or penetrating oil spray lubricant or penetrating oil
anti-seize
anti-seize anti-seize anti-seize
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 air of channel lock pliers air of channel lock pliers air of channel lock pliers
T T T T O O O O ST ST ST ST ART ART ART ART ::::
A (For 1521)
ail pipe approximately 1" behind
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.
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 t
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.
1. Remove and inventory new JBA
exhaust.
exhaust. exhaust. exhaust.
head pipe (A) using the 2-1/2" clamp (E).
ighten completely with 9/16" deep wall
8. Using some form of heat and force, 8. Using some form of heat and force, 8. Using some form of heat and force, 8. 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.
9. 9. 9. 9. 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
T T T T
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.
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.
ail pipe and tighten 3"
13. Inst 13. Inst 13. Inst 13. 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.
14. Inst 14. Inst 14. Inst 14. 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 t
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.
1" rearward when exhaust temperature
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
st st st start to rise. art to rise. art to rise. art to rise.
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.
ighten clamp (H) completely
using 9/16" deep wall socket.
19. 19. 19. 19. T T T T
Note: Note: Note: Note: Use anti-seize on threads. Use anti-seize on threads. Use anti-seize on threads. Use anti-seize on threads.
11. Using the 3" clamp (F), tighten clamp
completely using 9/16" deep wall socket.
10. With JBA logo facing rear of vehicle, 10. With JBA logo facing rear of vehicle, 10. With JBA logo facing rear of vehicle, 10. 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. all turn out clamp (H) 15. Inst 15. Inst 15. Inst 15. Inst
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.
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.
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. Inst 12. Inst 12. Inst 12. 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....
ate to desired position approx. 1"
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) rot
from body
from body from body from body....
17039a 17039a 17039a 17039a
W W We e e recommend t recommend t recommend t aking the truck to a muffler shop and having all slip connections tack welded. We
7-3-02