JBA 40-2509 - 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.
40-2509
1988-94 Ford F-250, F-350 1988-94 Ford F-250, F-350 1988-94 Ford F-250, F-350 1988-94 Ford F-250, F-350
V8-5.8L, 7.5L
V8-5.8L, 7.5L V8-5.8L, 7.5L V8-5.8L, 7.5L Ext. cab/Long bed Ext. cab/Long bed Ext. cab/Long bed Ext. cab/Long bed
T T T T OOLS RECOMMENDED: OOLS RECOMMENDED: OOLS RECOMMENDED: OOLS RECOMMENDED:
ratchet ratchet ratchet ratchet
9/16 deep socket
9/16 deep socket 9/16 deep socket 9/16 deep socket
15mm deep socket
15mm deep socket 15mm deep socket 15mm deep socket
9/16" box wrench
9/16" box wrench 9/16" box wrench 9/16" box wrench
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, 12" air of channel lock pliers, 12" air of channel lock pliers, 12" air of channel lock pliers, 12"
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
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 E. E. E. E. 2-1/2" H.P 2-1/2" H.P 2-1/2" H.P 2-1/2" H.P. clamp . clamp . clamp . clamp 1 1 1 1
B. B. B. B. Muf Muf Muf Muffler fler fler fler, 24" , 24" , 24" , 24" 1 1 1 1 F F F F.... Front muf Front muf Front muf Front muffler 3" clamp/hanger fler 3" clamp/hanger fler 3" clamp/hanger fler 3" clamp/hanger 1 1 1 1
C. C. C. C. T T T Tail pipe ail pipe ail pipe ail pipe 1 1 1 1 G G G G.... Rear muf Rear muf Rear muf Rear muffler 3" fler 3" fler 3" fler 3" clamp/hanger clamp/hanger clamp/hanger clamp/hanger 1 1 1 1
D. D. D. D. T T T Turn out urn out urn out urn out 1 1 1 1 H. H. H. H. T T T Turn out 3" clamp/hanger w/shield urn out 3" clamp/hanger w/shield urn out 3" clamp/hanger w/shield urn out 3" clamp/hanger w/shield 1 1 1 1
D
B
G
F
A
E
C
D
B
G
F
A
E
C
D
B
G
F
A
E
C
D
B
G
F
A
E
C
H H H H
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.
18. Inst 18. Inst 18. Inst 18. Install turn out (D) over end of t all turn out (D) over end of t all turn out (D) over end of t all turn out (D) over end of tail pipe ail pipe ail pipe ail pipe
(C) and tighten clamp/hanger (H) lightly with (C) and tighten clamp/hanger (H) lightly with (C) and tighten clamp/hanger (H) lightly with (C) and tighten clamp/hanger (H) lightly wi
9/16" wrench.
9/16" wrench. 9/16" wrench. 9/16" wrench. NOTE: NOTE: NOTE: NOTE: Put anti-seize on Put anti-seize on Put anti-seize on Put anti-seize on
threads. threads. threads. threads.
th
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 pipes approximately 3" ail pipes approximately 3" ail pipes approximately 3" ail pipes approximately 3"
behind rear of muf behind rear of muf behind rear of muf behind rear of muffler fler fler fler....
4. S 4. S 4. S 4. Spray lubricant on rear t pray lubricant on rear t pray lubricant on rear t pray lubricant on rear tail pipe hanger ail pipe hanger ail pipe hanger ail pipe hanger
rubber grommet. rubber grommet. rubber grommet. rubber grommet.
8. S 8. S 8. S 8. Spray lubricant on front and rear muf pray lubricant on front and rear muf pray lubricant on front and rear muf pray lubricant on front and rear muffler fler fler fler
hanger rod grommet hanger rod grommet hanger rod grommet hanger rod grommets. s. s. s.
13. Inst 13. Inst 13. Inst 13. Install 3" clamp/hanger (F) into front all 3" clamp/hanger (F) into front all 3" clamp/hanger (F) into front all 3" clamp/hanger (F) into front
muf muf muf muffler hanger rubber grommet and position fler hanger rubber grommet and position fler hanger rubber grommet and position fler hanger rubber grommet and position
clamp over end of end of head pipe (A). clamp over end of end of head pipe (A). clamp over end of end of head pipe (A). clamp over end of end of head pipe (A).
14. Inst 14. Inst 14. Inst 14. Install muf all muf all muf all muffler (B) over head pipe (A) fler (B) over head pipe (A) fler (B) over head pipe (A) fler (B) over head pipe (A)
with JBA logo towards rear of vehicle with JBA logo towards rear of vehicle with JBA logo towards rear of vehicle with JBA logo towards rear of vehicle
making sure muf
making sure muf making sure muf making sure muffler bottoms out on slip fler bottoms out on slip fler bottoms out on slip fler bottoms out on slip
joint. joint. joint. joint.
19. Position 3" clamp/hanger (F), level and 19. Position 3" clamp/hanger (F), level and 19. Position 3" clamp/hanger (F), level and 19. Position 3" clamp/hanger (F), level an
tighten completely using 9/16" seep socket.
tighten completely using 9/16" seep socket. tighten completely using 9/16" seep socket. tighten completely using 9/16" seep socke
NOTE: NOTE: NOTE: NOTE: Use anti-seize on threads. Use anti-seize on threads. Use anti-seize on threads. Use anti-seize on threads.
20. Position t 20. Position t 20. Position t 20. Position tail pipe (C) to desired position ail pipe (C) to desired position ail pipe (C) to desired position ail pipe (C) to desired positio
and tighten 3" clamp/hanger (G) completely and tighten 3" clamp/hanger (G) completely and tighten 3" clamp/hanger (G) completely and tighten 3" clamp/hanger (G) complete
using 9/16" deep socket.
using 9/16" deep socket. using 9/16" deep socket. using 9/16" deep socket.
d
t.
n
ly
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 t remove t remove t remove tail pipe hanger rod from rubber ail pipe hanger rod from rubber ail pipe hanger rod from rubber ail pipe hanger rod from rubber
grommet. grommet. grommet. grommet.
9. With muf 9. With muf 9. With muf 9. With muffler supported, using channel fler supported, using channel fler supported, using channel fler supported, using channel
lock pliers, remove front and rear muf lock pliers, remove front and rear muf lock pliers, remove front and rear muf lock pliers, remove front and rear muffler fler fler fler
hanger rods from rubber grommet hanger rods from rubber grommet hanger rods from rubber grommet hanger rods from rubber grommets. s. s. s.
15. Inst 15. Inst 15. Inst 15. Install 3" clamp/hanger (G) into rear all 3" clamp/hanger (G) into rear all 3" clamp/hanger (G) into rear all 3" clamp/hanger (G) into rear
muf muf muf muffler rubber grommet fler rubber grommet fler rubber grommet fler rubber grommets with flat bar s with flat bar s with flat bar s with flat bar
towards driver side. Slip clamp/hanger (G) towards driver side. Slip clamp/hanger (G) towards driver side. Slip clamp/hanger (G) towards driver side. Slip clamp/hanger (G)
over end of slip joint of muf
over end of slip joint of muf over end of slip joint of muf over end of slip joint of muffler (B). Hand fler (B). Hand fler (B). Hand fler (B). Hand
22. 22. 22. 22. Af Af Af After inst ter inst ter inst ter installation, it is recommended that allation, it is recommended that allation, it is recommended that allation, it is recommended th
all clamp all clamp all clamp all clamps be retightened and joint s be retightened and joint s be retightened and joint s be retightened and joints t s t s t s tack ack ack ack
welded in 3 spot welded in 3 spot welded in 3 spot welded in 3 spots. s. s. s.
21. Rot 21. Rot 21. Rot 21. Rotate turn out (D) to desired position ate turn out (D) to desired position ate turn out (D) to desired position ate turn out (D) to desired position
and tighten 3î clamp/hanger (H) completely and tighten 3î clamp/hanger (H) completely and tighten 3î clamp/hanger (H) completely and tighten 3î clamp/hanger (H) completel
23. Using a sof 23. Using a sof 23. Using a sof 23. Using a soft cloth, remove all print t cloth, remove all print t cloth, remove all print t cloth, remove all prints from s from s from s fro
turn out tip. turn out tip. turn out tip. turn out tip.
at
m
y....
6. Remove t 6. Remove t 6. Remove t 6. Remove tail pipe assembly from rear of ail pipe assembly from rear of ail pipe assembly from rear of ail pipe assembly from rear of
vehicle. vehicle. vehicle. vehicle.
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 assembly fler assembly fler assembly fler assembly
without damaging converter pipe. without damaging converter pipe. without damaging converter pipe. without damaging converter pipe.
tighten clamp at this time. tighten clamp at this time. tighten clamp at this time. tighten clamp at this time.
NOTE: NOTE: NOTE: NOTE: Use anti-seize on threads. Use anti-seize on threads. Use anti-seize on threads. Use anti-seize on threads.
16. Inst 16. Inst 16. Inst 16. Install t all t all t all tail pipe (C) into muf ail pipe (C) into muf ail pipe (C) into muf ail pipe (C) into muffler (B) fler (B) fler (B) fler (B)
from rear of vehicle. Longest end towards from rear of vehicle. Longest end towards from rear of vehicle. Longest end towards from rear of vehicle. Longest end towards
muf
muf muf muffler making sure t fler making sure t fler making sure t fler making sure tail pipe bottoms out ail pipe bottoms out ail pipe bottoms out ail pipe bottoms out
in slip joint. in slip joint. in slip joint. in slip joint.
24. Lower vehicle and reatt 24. Lower vehicle and reatt 24. Lower vehicle and reatt 24. Lower vehicle and reattach the negative ach the negative ach the negative ach the negativ
battery cable. battery cable. battery cable. battery cable.
NOTES: NOTES: NOTES: NOTES:
1) It may be necessary to loosen and realign 1) It may be necessary to loosen and realign 1) It may be necessary to loosen and realign 1) It may be necessary to loosen and reali
the sp
the sp the sp the spare tire for proper clearance. are tire for proper clearance. are tire for proper clearance. are tire for proper clearance.
gn
e
1 1 1 11. Inst 1. Inst 1. Inst 1. Install head pipe (A) aligning notch all head pipe (A) aligning notch all head pipe (A) aligning notch all head pipe (A) aligning notch
with locating pin. with locating pin. with locating pin. with locating pin. NOTE: NOTE: NOTE: NOTE: Make sure pin is Make sure pin is Make sure pin is Make sure pin is
bottomed out in notch. bottomed out in notch. bottomed out in notch. bottomed out in notch.
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 1" and about 1" and about 1" and about 1
rearward when exhaust temperature st rearward when exhaust temperature st rearward when exhaust temperature st rearward when exhaust temperature start to art to art to art
rise. rise. rise. 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.
to
"
7. S 7. S 7. S 7. Spray penetrating lubricant on front pray penetrating lubricant on front pray penetrating lubricant on front pray penetrating lubricant on front
head pipe clamp threads at rear of con- head pipe clamp threads at rear of con- head pipe clamp threads at rear of con- head pipe clamp threads at rear of con­
verter and remove using a 15mm deep
verter and remove using a 15mm deep verter and remove using a 15mm deep verter and remove using a 15mm deep
socket..
socket.. socket.. socket..
12. Inst 12. Inst 12. Inst 12. Install 2-1/2" clamp (E) on front por- all 2-1/2" clamp (E) on front por- all 2-1/2" clamp (E) on front por- all 2-1/2" clamp (E) on front por­
tion of head pipe (A). tion of head pipe (A). tion of head pipe (A). tion of head pipe (A). T T T Tighten completely ighten completely ighten completely ighten completely
with 9/16" deep socket. with 9/16" deep socket. with 9/16" deep socket. with 9/16" deep socket. NOTE: NOTE: NOTE: NOTE: Use anti- Use anti- Use anti- Use anti­
seize on threads. seize on threads. seize on threads. seize on threads.
17. Inst 17. Inst 17. Inst 17. Install 3" clamp/hanger with heat all 3" clamp/hanger with heat all 3" clamp/hanger with heat all 3" clamp/hanger with heat
shield (H) into rear t shield (H) into rear t shield (H) into rear t shield (H) into rear tail pipe rubber grom- ail pipe rubber grom- ail pipe rubber grom- ail pipe rubber grom­
met. Slip clamp over end of t met. Slip clamp over end of t met. Slip clamp over end of t met. Slip clamp over end of tail pipe (C). ail pipe (C). ail pipe (C). ail pipe (C).
17041 17041 17041 17041
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.
6-20-02 6-20-02 6-20-02 6-20-02