JBA 40-2522 - 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 Parts List s List s List s List 40-2522
A. A. A. A. Head pipe Head pipe Head pipe Head pipe 1 1 1 1 E. E. E. E. 2-1/2" clamp 2-1/2" clamp 2-1/2" clamp 2-1/2" clamp 1 1 1 1
B. B. B. B. 24" muf 24" muf 24" muf 24" muffler fler fler fler 1 1 1 1 F F F F.... 3" clamp 3" clamp 3" clamp 3" clamp 1 1 1 1 1999-00 Ford F-150 Ext/S 1999-00 Ford F-150 Ext/S 1999-00 Ford F-150 Ext/S 1999-00 Ford F-150 Ext/Sttttd d d d 2/4 WD 2/4 WD 2/4 WD 2/4 WD
C. C. C. C. T T T Tail pipe ail pipe ail pipe ail pipe 1 1 1 1 G G G G.... 3" muf 3" muf 3" muf 3" muffler clamp/hanger fler clamp/hanger fler clamp/hanger fler 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. 3" t 3" t 3" t 3" tail pipe clamp ail pipe clamp ail pipe clamp ail pipe clamp 1 1 1 1
E E E E
V8-4.6L, V8- 5.4L V8-4.6L, V8- 5.4L V8-4.6L, V8- 5.4L V8-4.6L, V8- 5.4L
F F F F
1998 5.4L 1998 5.4L 1998 5.4L 1998 5.4L V8 V8 V8 V8
G G G G
T T T TOOLS RECOMMENDED: OOLS RECOMMENDED: OOLS RECOMMENDED: OOLS RECOMMENDED:
H H H H
ratchet ratchet ratchet ratchet rubber mallet rubber mallet rubber mallet rubber mallet
9/16 deep socket 9/16 deep socket 9/16 deep socket 9/16 deep socket spray lubricant or penetrating spray lubricant or penetrating spray lubricant or penetrating spray lubricant or penetrating
15mm socket 15mm socket 15mm socket 15mm socket oil oil oil oil
p p p pair of channel lock pliers air of channel lock pliers air of channel lock pliers air of channel lock pliers prybar prybar prybar prybar
reciprocating saw or hack reciprocating saw or hack reciprocating saw or hack reciprocating saw or hack imp imp imp impact wrench act wrench act wrench act wrench
saw saw saw saw anti-seize anti-seize anti-seize anti-seize
8mm wrench 8mm wrench 8mm wrench 8mm wrench
D D D D A A A A
T T T TO O O O ST ST ST START ART ART ART::::
B
C
B
C
B
C
B
C
2. Disconnect negative battery cable with 2. Disconnect negative battery cable with 2. Disconnect negative battery cable with 2. Disconnect negative battery cable with
8 mm wrench and allow vehicle exhaust
8 mm wrench and allow vehicle exhaust 8 mm wrench and allow vehicle exhaust 8 mm wrench and allow vehicle exhaust
to cool.
to cool. to cool. 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. Install muffler.
19. Inst 19. Inst 19. Inst 19. Install rear t all rear t all rear t all rear tail pipe hanger into ail pipe hanger into ail pipe hanger into ail pipe hanger into
lower hole of rubber grommet. Rot lower hole of rubber grommet. Rot lower hole of rubber grommet. Rot lower hole of rubber grommet. Rotate ate ate ate
ttttail pipe (C) to align rear hanger rod. ail pipe (C) to align rear hanger rod. ail pipe (C) to align rear hanger rod. ail pipe (C) to align rear hanger rod.
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 the t , cut the t , cut the t , cut the tail pipe approximately 3î ail pipe approximately 3î ail pipe approximately 3î ail pipe approximately 3î
behind muf behind muf behind muf behind muffler fler fler fler....
8. Using a p 8. Using a p 8. Using a p 8. Using a pair of channel lock pliers, air of channel lock pliers, air of channel lock pliers, air of channel lock pliers,
remove rubber grommet remove rubber grommet remove rubber grommet remove rubber grommets completely and s completely and s completely and s completely and
save. save. save. save. They will be reinst They will be reinst They will be reinst They will be reinstalled alled alled alled ....
14. Slip muf 14. Slip muf 14. Slip muf 14. Slip muffler hanger (G) over end of fler hanger (G) over end of fler hanger (G) over end of fler hanger (G) over end of
20. 20. 20. 20. T T T Tighten 3" clamp/hanger (G) com- ighten 3" clamp/hanger (G) com- ighten 3" clamp/hanger (G) com- ighten 3" clamp/hanger (G) com-
pletely with 9/16" deep socket. pletely with 9/16" deep socket. pletely with 9/16" deep socket. pletely with 9/16" deep socket.
muf muf muf muffler (B) and hand tighten only fler (B) and hand tighten only fler (B) and hand tighten only fler (B) and hand tighten only....
15. Rot 15. Rot 15. Rot 15. Rotate head pipe (A) to desired posi- ate head pipe (A) to desired posi- ate head pipe (A) to desired posi- ate head pipe (A) to desired posi-
tion. tion. tion. tion.
NOTE: NOTE: NOTE: NOTE: use anti-seize on threads. use anti-seize on threads. use anti-seize on threads. use anti-seize on threads.
(C).
).
4. S 4. S 4. S 4. Spray lubricant on lower rubber hanger pray lubricant on lower rubber hanger pray lubricant on lower rubber hanger pray lubricant on lower rubber hanger
grommet on rear section of t grommet on rear section of t grommet on rear section of t grommet on rear section of tail pipe. ail pipe. ail pipe. ail pipe.
5. Using channel lock pliers, remove rear 5. Using channel lock pliers, remove rear 5. Using channel lock pliers, remove rear 5. Using channel lock pliers, remove rear
ttttail pipe hanger rod
ail pipe hanger rod ail pipe hanger rod ail pipe hanger rod from lower hole of from lower hole of from lower hole of from lower hole of
rubber grommet. rubber grommet. rubber grommet. rubber grommet.
9. Lubricate front muf 9. Lubricate front muf 9. Lubricate front muf 9. Lubricate front muffler clamp bolt fler clamp bolt fler clamp bolt fler clamp bolts and s and s and s and
using a 15 mm socket, loosen and using a 15 mm socket, loosen and using a 15 mm socket, loosen and using a 15 mm socket, loosen and
remove clamp.
remove clamp. remove clamp. remove clamp.
10. Using some form of force, or heat, 10. Using some form of force, or heat, 10. Using some form of force, or heat, 10. Using some form of force, or heat,
disengage and remove muf
disengage and remove muf disengage and remove muf disengage and remove muffler fler fler fler....
Note: Note: Note: Note: Do Not Damage stock head Do Not Damage stock head Do Not Damage stock head Do Not Damage stock headpipe. pipe. pipe. pipe.
16. Put anti-seize on threads of 2" 16. Put anti-seize on threads of 2" 16. Put anti-seize on threads of 2" 16. Put anti-seize on threads of 2"
clamp (E) and inst
clamp (E) and inst clamp (E) and inst clamp (E) and install on front of head- all on front of head- all on front of head- all on front of head-
pipe with 9/16" deep wall socket. pipe with 9/16" deep wall socket. pipe with 9/16" deep wall socket. pipe with 9/16" deep wall socket.
T
T T Tightening completely ightening completely ightening completely ightening completely....
Note: Note: Note: Note: make sure clamp is on the rear make sure clamp is on the rear make sure clamp is on the rear make sure clamp is on the rear
side of pin as close as possible. side of pin as close as possible. side of pin as close as possible. side of pin as close as possible.
17. 17. 17. 17. Put anti-seize on 3" clamp (F) and Put anti-seize on 3" clamp (F) and Put anti-seize on 3" clamp (F) and Put anti-seize on 3" clamp (F) and
inst inst inst install to front slip of muf all to front slip of muf all to front slip of muf all to front slip of muffler fler fler fler. Position . Position . Position . Position
clamp 1/2" from lip and tighten completely clamp 1/2" from lip and tighten completely clamp 1/2" from lip and tighten completely clamp 1/2" from lip and tighten completely
with 9/16" socket.
with 9/16" socket. with 9/16" socket. with 9/16" socket.
22. Rot 22. Rot 22. Rot 22. Rotate turn out (D) to desired posi- ate turn out (D) to desired posi- ate turn out (D) to desired posi- ate turn out (D) to desired posi-
tion, leaving clearance from body tion, leaving clearance from body tion, leaving clearance from body tion, leaving clearance from body....
Position 3" clamp (H) over slip joint and
Position 3" clamp (H) over slip joint and Position 3" clamp (H) over slip joint and Position 3" clamp (H) over slip joint and
tighten completely using 9/16" deep
tighten completely using 9/16" deep tighten completely using 9/16" deep tighten completely using 9/16" deep
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.
21. Slip 3" clamp (H) over end of t 21. Slip 3" clamp (H) over end of t 21. Slip 3" clamp (H) over end of t 21. Slip 3" clamp (H) over end of tail pipe (C). ail pipe (C). ail pipe (C). ail pipe
Inst Inst Inst 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 (C). ail pipe (C). ail pipe (C). ail pipe (C
6. Remove t 6. Remove t 6. Remove t 6. Remove tail pipe assembly from the ail pipe assembly from the ail pipe assembly from the ail pipe assembly from the
rear of vehicle. rear of vehicle. rear of vehicle. rear of vehicle.
1 1 1 11. Inst 1. Inst 1. Inst 1. Install JBA head all JBA head all JBA head all JBA head pipe (A), aligning pipe (A), aligning pipe (A), aligning pipe (A), aligning
notch with locating pin. notch with locating pin. notch with locating pin. notch with locating pin. Note: Note: Note: Note: Make sure Make sure Make sure Make sure
pin is bottomed out in notch. pin is bottomed out in notch. pin is bottomed out in notch. pin is bottomed out in notch.
7. S 7. S 7. S 7. Spray lubricant on all holes of muf pray lubricant on all holes of muf pray lubricant on all holes of muf pray lubricant on all holes of muffler fler fler fler
hanger grommet hanger grommet hanger grommet hanger grommets. s. s. s.
12. Reinst 12. Reinst 12. Reinst 12. Reinstall two rubber grommet all two rubber grommet all two rubber grommet all two rubber grommets to s to s to s to
stock hangers and inst stock hangers and inst stock hangers and inst stock hangers and install muf all muf all muf all muffler hang- fler hang- fler hang- fler hang-
er (G) thru lower holes of grommet. er (G) thru lower holes of grommet. er (G) thru lower holes of grommet. er (G) thru lower holes of grommet.
Note: Note: Note: Note: longer end of hanger is to go on longer end of hanger is to go on longer end of hanger is to go on longer end of hanger is to go on
drivers side, looking from rear drivers side, looking from rear drivers side, looking from rear drivers side, looking from rear....
18. Inst 18. Inst 18. Inst 18. Install t all t all t all tail pipe (C) from rear of vehicle, ail pipe (C) from rear of vehicle, ail pipe (C) from rear of vehicle, ail pipe (C) from rear of vehicle,
and slip into muf and slip into muf and slip into muf and slip into muffler fler fler fler.... Note: Note: Note: Note: make sure that make sure that make sure that make sure that
the end of the t the end of the t the end of the t the end of the tail pipe with the hanger is ail pipe with the hanger is ail pipe with the hanger is ail pipe with the hanger is
at the rear of the vehicle. at the rear of the vehicle. at the rear of the vehicle. at the rear of the vehicle.
23. Reatt 23. Reatt 23. Reatt 23. Reattach the negative battery cable. ach the negative battery cable. ach the negative battery cable. ach the negative battery cable.
24. 24. 24. 24. 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
be t be t be t be tack welded in 3 spot ack welded in 3 spot ack welded in 3 spot ack welded in 3 spots s s s
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.
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.
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. 6.13.06