JBA 40-2536 - Manual

INSTALLATION INSTRUCTIONS
**Installation recommendation: JBA recommends in most cases that the vehicle be taken to a reputable exhaust shop.
40-2536
04-07 Ford F-150 4.6/5.4L 3v V8
Parts List: TOOLS RECOMMENDED:
A. Intermediate pipe 1
ratchet
B. JBA high flow muffler 1
socket set
C. Y-pipe transition 1
channel lock pliers
D. Passenger side axle pipe 1
rubber mallet E. Passenger side tail pipe w/ tip 1
spray lubricant F Driver side axle pipe 1
G Driver side tail pipe w/ tip 1 anti-seize (for stainless)
H 3" Clamp 1 pry bar
I 3" Clamp w/ hanger 1
J. 2-1/2" clamp 7
K. Hanger w/ hardware 2
L. Heat shield 8" (not shown) 1
B C D E
A
H J
J K
J
I
F
G
Cut intermediat pipe (A) to length indicated.
Measure from keyway.
Cut "A" length:
Std Cab / SB: 22-1/4"
Std Cab / LB: 39-1/4"
Ext Cab / SB: 39-1/4"
Ext Cab / LB: 51-1/4"
SuperCrew: 33-3/4"
Start:
For 30-2535 and 50-2535 Only 12. Snug the 3" clamp with 18. Slip the 2.5" clamp over the
1. Remove and inventory new For Super cab/short bed trucks hanger (G) on the front of the rear of the axle pipes.
JBA exhaust system. relocate the front muffler hanger JBA muffler (B).
2. Disconnect negative battery to the hole on the side of the
cable and allow vehicle to cool. frame.
3. Loosen the clamp connecting 19. Slide the JBA tail pipes with
the factory intermediate pipe to tips over on to the axle pipes
the head pipe assembly.
Old position
New position
13. Slip the supplied Y-pipe over
the end of the JBA muffler and
insert hanger into rubber
isolator
with 1" clearance on rear
bumper.
4. Then slide the clamp back.
8. Slip the supplied 2-1/2" clamp
on to the factory head pipe
assembly.
14. Slip a 3" clamp on the front
of the Ypipe (C).
20. Position supplied hanger as
shown with 2.5" clamp in place.
Mark the position of the top hole
on hanger. Drill a hole in spring
hanger (5/16), and fasten
hanger with hardware supplied.
5. Spray the rubber isolator
hangers with WD40 or similar
lubricant. 9. Install the supplied
intermediate pipe (A) onto the
factory head pipe (cut to length
for your vehicle. Make sure to
line up the keyway.
15. Install the driver side and
passenger side axle pipes into
the new JBA ypipe and secure
with supplied 2.5" clamps.
21. Align the tail pipes for
clearance around spare tire and
rear axle. Adjust tips to be even
with bumper and equal distance
from center.
6. Using a pry bar, push the 22. Secure the tail pipes in place
exhaust system back until the by tightening the 2.5" clamps.
exhaust hangers drop free from 23. Using a soft cloth, remove
the rubber isolators. Caution: all prints from the exhaust tip.
Be careful not to let the exhaust
system fall on you or damage
the rear fender.
10. Insert the 3" clamp with
hanger into the front rubber
isolator hanger.
16. Re-arrange rear axle vent
line, brake line and vapor line to
allow proper clearance for tail
pipe. Protect the lines with the
supplied 8" heat shield.
24. Check all clamps and
connections for proper fit and
alignment. Double check all
clamps are tightened and that all
hangers are secure in rubber
grommets. It is recommended
that after installation of this
system you have all slip
connections tack welded by a
muffler shop.
NOTES:
7. Carefully lower the exhaust 1.) It may be necessary to
system and remove it from the
vehicle.
11. Slip the JBA muffler (B) onto
the intermediate pipe (C) with
the "inlet" sticker towards the
front of the vehicle.
loosen and realign the spare tire
for proper clearance.
2.) All exhaust systems expand
about 1" rearward when exhaust
temperature rises.
17. Check the alignment of the
installed system then tight the
clamps on the intermediate pipe
(A) and muffler (B).
3.) Use anti-seize on threads of
stainless steel clamps.
9.20.07 We recommend taking the vehicle to a muffler shop and having all slip connections tack welded.