JBA 40-3001 - Manual

INSTALLATION INSTRUCTIONS
**Inst allation recommendation:
JBA recommends in most cases that the vehicle be taken to a reputable exhaust shop.
40-3001
G
1996-1998 GM Pickup V8-5.7L E/S
Parts List
A. Head pipe 1
TOOLS RECOMMENDED:
B. Muffler 24" 1
reciprocating saw or hack saw C. Tail pipe 1
prybar D. Turn out 1
rubber mallet E. Front muffler clamp 3" 1
ratchet F. Rear muffler clamp/hanger 3" 1
15mm deep socket G. Turn out clamp 3" 1
9/16 box wrench or socket
7/8" open end wrench
pair of channel lock pliers
13mm socket
C
anti-seize
impact wrench
D
B
F
E
A
TO START:
spray lubricant or penetrating oil
2. Disconnect negative battery cable and
allow vehicle exhaust to cool.
1. Remove and inventory new JBA
exhaust.
8. Remove three nuts on three bolt flange
using 15mm socket. You may want to use
some penetrating oil.
16. With muffler (B) in place, install muf­
fler clamp (E) on slip fit joint. Position 1/4"
from lip. Tighten clamp completely with
9/16" deep wall socket. NOTE: Use some
anti-seize on all threads.
3. With vehicle raised and properly sup­
ported, using a reciprocating saw or hack
saw, cut the tail pipe approximately 3"
behind rear muffler hanger. 10. Using a pair of channel lock pliers,
remove front and rear muffler hanger rods
from bottom holes of grommets.
Note: support muffler before starting.
17. Install rear muffler clamp/hanger (F)
over slip joint on rear of muffler. Do not
tighten at this time.
23. Position rear muffler clamp/hanger (F)
1/4" from lip on slip joint and tighten com­
pletely with 9/16" deep wall socket. Note:
Use anti-seize on threads.
4. Spray lubricant on rear tail pipe hanger
grommet.
11. Remove muffler assembly pulling
towards rear of vehicle. Note: use care not
to damage gasket on three bolt flange.
18. Slip clamp/hanger (F) into lower hole
on rubber grommet.
5. Using a pair of channel lock pliers,
remove hanger rod from bottom hole of
grommet.
6. Remove tail pipe assembly from the
rear of vehicle.
12. Install head pipe (A) with three bolt
flange. Install hanger through lower hole
in rubber grommet. Tighten three nuts
using 15mm socket. Note: we recom­
mend using anti-seize on threads.
19. Install tail pipe (C) from rear into slip
joint on muffler (B). Slip approx. 2".
20. Slip rear tail pipe (C) hanger into
lower hole in rubber grommet.
25. Using a soft cloth, remove all prints
from turnout tip.
26. Lower vehicle and reattach the nega­
tive battery cable.
NOTES:
1) It may be necessary to loosen and
realign the spare tire for proper clear­
ance.
2) All exhaust systems will expand about
1" rearward when exhaust temperature
start to rise.
3) Use Anti-seize on threads of clamps D,
E and F.
24. Slip turn out clamp (G) onto tail pipe.
Slip turn out (D) on tail pipe (C) approx.
1-1/2". Rotate tip to desired position leav­
ing clearance from body. Position clamp
(G) with threads in an upward position.
Tighten completely with 9/16" deep wall
socket. Note: use anti-seize on threads.
7. Spray lubricant on front and rear muffler
hanger grommets.
13. Install oxygen sensor using 7/8"
wrench.
21. Position tail pipe (C) so hanger is not
cocked at an angle, and rubber grommet
is angled forward.
22. Inspect clearance around rear-end
shock and spare tire.
9. Remove oxygen sensor with 7/8" open
end wrench.
14. Slip muffler (B) on head pipe approxi­
mately 2". Note: You may have to tap it in
with a rubber mallet. Make sure JBA logo
is to the rear.
17092
We recommend taking the vehicle to an exhaust shop to have all slip connections tack welded.
7-17-02