JBA 40-3003 - 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.
40-3003
GM Pickup GM Pickup GM Pickup GM Pickup
96-98 V8-5.7L
96-98 V8-5.7L 96-98 V8-5.7L 96-98 V8-5.7L S S S Sttttd. cab, S d. cab, S d. cab, S d. cab, Sttttd. bed d. bed d. bed d. bed
Part Part Part Part s List s List s List s List
T T T T OOLS RECOMMENDED: OOLS RECOMMENDED: OOLS RECOMMENDED: OOLS RECOMMENDED:
A. A. A. A. Head pipe with hanger Head pipe with hanger Head pipe with hanger Head pipe with hanger 1 1 1 1
reciprocating saw or hack saw reciprocating saw or hack saw reciprocating saw or hack saw reciprocating saw or hack saw B. B. B. B. Muf Muf Muf Muffler 24" fler 24" fler 24" fler 24" 1 1 1 1
prybar prybar prybar prybar C. C. C. C. T T T Tail pipe with hanger ail pipe with hanger ail pipe with hanger ail pipe with hanger 1 1 1 1
rubber mallet rubber mallet rubber mallet rubber mallet D. D. D. D. T T T Turn out urn out urn out urn out 1 1 1 1
ratchet ratchet ratchet ratchet E. E. E. E. Front muf Front muf Front muf Front muffler clamp 3" fler clamp 3" fler clamp 3" fler clamp 3" 1 1 1 1
15mm deep socket 15mm deep socket 15mm deep socket 15mm deep socket F F F F.... Rear muf Rear muf Rear muf Rear muffler clamp/hanger 3" fler clamp/hanger 3" fler clamp/hanger 3" fler clamp/hanger 3" 1 1 1 1
9/16 box wrench or socket 9/16 box wrench or socket 9/16 box wrench or socket 9/16 box wrench or socket G G G G.... T T T Turn out clamp 3" urn out clamp 3" urn out clamp 3" urn out clamp 3" 1 1 1 1
7/8" open end wrench 7/8" open end wrench 7/8" open end wrench 7/8" open end wrench
p
p p pair of channel lock pliers air of channel lock pliers air of channel lock pliers air of channel lock pliers
13mm socket 13mm socket 13mm socket 13mm socket C C C C
anti-seize anti-seize anti-seize anti-seize
imp
imp imp impact wrench act wrench act wrench act wrench
D
B
G
F E
A
D
B
G
F E
A
D
B
G
F E
A
D
B
G
F E
A
T T T T O O O O ST ST ST ST ART ART ART ART ::::
spray lubricant or penetrating oil spray lubricant or penetrating oil spray lubricant or penetrating oil spray lubricant or penetrating oil
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.
9. Remove three nut 9. Remove three nut 9. Remove three nut 9. Remove three nuts on three bolt flange s on three bolt flange s on three bolt flange s on three bolt flange
using 15mm socket. using 15mm socket. using 15mm socket. using 15mm socket. Y Y Y You may want to use ou may want to use ou may want to use ou may want to use
some penetrating oil. some penetrating oil. some penetrating oil. some penetrating oil.
15. With muf 15. With muf 15. With muf 15. With muffler (B) in place, inst fler (B) in place, inst fler (B) in place, inst fler (B) in place, install muf- all muf- all muf- all muf­
fler clamp (E) on slip fit joint. Position 1/4" fler clamp (E) on slip fit joint. Position 1/4" fler clamp (E) on slip fit joint. Position 1/4" fler clamp (E) on slip fit joint. Position 1/4"
from lip.
from lip. from lip. from lip. T T T Tighten clamp completely with ighten clamp completely with ighten clamp completely with ighten clamp completely with
9/16" deep wall socket. NOTE: Use some 9/16" deep wall socket. NOTE: Use some 9/16" deep wall socket. NOTE: Use some 9/16" deep wall socket. NOTE: Use some
anti-seize on all threads.
anti-seize on all threads. anti-seize on all threads. anti-seize on all threads.
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 3" ail pipe approximately 3" ail pipe approximately 3" ail pipe approximately 3"
behind rear muf behind rear muf behind rear muf behind rear muffler hanger fler hanger fler hanger fler hanger....
10. Using a p 10. Using a p 10. Using a p 10. Using a pair of channel lock pliers, air of channel lock pliers, air of channel lock pliers, air of channel lock pliers,
remove front and rear muf remove front and rear muf remove front and rear muf remove front and rear muffler hanger rods fler hanger rods fler hanger rods fler hanger rods
from bottom holes of grommet from bottom holes of grommet from bottom holes of grommet from bottom holes of grommets. s. s. s.
Note: Note: Note: Note: support muf support muf support muf support muffler before st fler before st fler before st fler before starting. arting. arting. arting.
16. Inst 16. Inst 16. Inst 16. Install rear muf all rear muf all rear muf all rear muffler clamp/hanger (F) fler clamp/hanger (F) fler clamp/hanger (F) fler clamp/hanger (F)
over slip joint on rear of muf over slip joint on rear of muf over slip joint on rear of muf over slip joint on rear of muffler fler fler fler. Do not . Do not . Do not . Do not
tighten at this time. tighten at this time. tighten at this time. tighten at this time.
22. Position rear muf 22. Position rear muf 22. Position rear muf 22. Position rear muffler clamp/hanger (F) fler clamp/hanger (F) fler clamp/hanger (F) fler clamp/hanger (F)
1/4" from lip on slip joint and tighten com- 1/4" from lip on slip joint and tighten com- 1/4" from lip on slip joint and tighten com- 1/4" from lip on slip joint and tighten com­
pletely with 9/16" deep wall socket. Note:
pletely with 9/16" deep wall socket. Note: pletely with 9/16" deep wall socket. Note: pletely with 9/16" deep wall socket. Note:
Use anti-seize on threads.
Use anti-seize on threads. Use anti-seize on threads. Use anti-seize on threads.
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
grommet. grommet. grommet. grommet.
1 1 1 11. Remove muf 1. Remove muf 1. Remove muf 1. Remove muffler assembly pulling fler assembly pulling fler assembly pulling fler assembly pulling
towards rear of vehicle. Note: use care not towards rear of vehicle. Note: use care not towards rear of vehicle. Note: use care not towards rear of vehicle. Note: use care not
to damage gasket on three bolt flange.
to damage gasket on three bolt flange. to damage gasket on three bolt flange. to damage gasket on three bolt flange.
17. Slip clamp/hanger (F) into lower hole 17. Slip clamp/hanger (F) into lower hole 17. Slip clamp/hanger (F) into lower hole 17. Slip clamp/hanger (F) into lower hole
on rubber grommet.
on rubber grommet. on rubber grommet. on rubber 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 rod from bottom hole of remove hanger rod from bottom hole of remove hanger rod from bottom hole of remove hanger rod from bottom hole of
grommet.
grommet. grommet. grommet.
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.
8. Remove oxygen sensor with 7/8" open 8. Remove oxygen sensor with 7/8" open 8. Remove oxygen sensor with 7/8" open 8. Remove oxygen sensor with 7/8" open
end wrench.
end wrench. end wrench. end wrench.
7. S 7. S 7. S 7. 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 grommet hanger grommet hanger grommet hanger grommets. s. s. s.
12. Inst 12. Inst 12. Inst 12. Install head pipe (A) with three bolt all head pipe (A) with three bolt all head pipe (A) with three bolt all head pipe (A) with three bolt
flange. Inst flange. Inst flange. Inst flange. Install hanger through lower hole all hanger through lower hole all hanger through lower hole all hanger through lower hole
in rubber grommet. in rubber grommet. in rubber grommet. in rubber grommet. T T T Tighten three nut ighten three nut ighten three nut ighten three nuts s s s
using 15mm socket. using 15mm socket. using 15mm socket. using 15mm socket. Note: Note: Note: Note: we recom- we recom- we recom- we recom­
mend using anti-seize on threads. mend using anti-seize on threads. mend using anti-seize on threads. mend using anti-seize on threads.
13. Inst 13. Inst 13. Inst 13. Install oxygen sensor using 7/8" all oxygen sensor using 7/8" all oxygen sensor using 7/8" all oxygen sensor using 7/8"
wrench. wrench. wrench. wrench.
14. Slip muf 14. Slip muf 14. Slip muf 14. Slip muffler (B) on head pipe approxi- fler (B) on head pipe approxi- fler (B) on head pipe approxi- fler (B) on head pipe approxi­
mately 2". Note: mately 2". Note: mately 2". Note: mately 2". Note: Y Y Y You may have to t ou may have to t ou may have to t ou may have to tap it in ap it in ap it in ap it in
with a rubber mallet. Make sure JBA logo with a rubber mallet. Make sure JBA logo with a rubber mallet. Make sure JBA logo with a rubber mallet. Make sure JBA logo
is to the rear
is to the rear is to the rear is to the rear....
18. Inst 18. Inst 18. Inst 18. Install t all t all t all tail pipe (C) from rear into slip ail pipe (C) from rear into slip ail pipe (C) from rear into slip ail pipe (C) from rear into slip
joint on muf joint on muf joint on muf joint on muffler (B). Slip approx. 2". fler (B). Slip approx. 2". fler (B). Slip approx. 2". fler (B). Slip approx. 2".
19. Slip rear t 19. Slip rear t 19. Slip rear t 19. Slip rear tail pipe (C) hanger into ail pipe (C) hanger into ail pipe (C) hanger into ail pipe (C) hanger into
lower hole in rubber grommet. lower hole in rubber grommet. lower hole in rubber grommet. lower hole in rubber grommet.
20. Position t 20. Position t 20. Position t 20. Position tail pipe (C) so hanger is not ail pipe (C) so hanger is not ail pipe (C) so hanger is not ail pipe (C) so hanger is not
cocked at an angle, and rubber grommet cocked at an angle, and rubber grommet cocked at an angle, and rubber grommet cocked at an angle, and rubber grommet
is angled forward.
is angled forward. is angled forward. is angled forward.
21. Inspect clearance around rear-end 21. Inspect clearance around rear-end 21. Inspect clearance around rear-end 21. Inspect clearance around rear-end
shock and sp
shock and sp shock and sp shock and spare tire. are tire. are tire. are tire.
24. Using a sof 24. Using a sof 24. Using a sof 24. 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.
25. Lower vehicle and reatt 25. Lower vehicle and reatt 25. Lower vehicle and reatt 25. 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
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 D, s D, s D, s D,
E and F E and F E and F E and F....
23. Slip turn out clamp (G) onto t 23. Slip turn out clamp (G) onto t 23. Slip turn out clamp (G) onto t 23. Slip turn out clamp (G) onto tail pipe. ail pipe. ail pipe. ail pipe.
Slip turn out (D) on t Slip turn out (D) on t Slip turn out (D) on t Slip turn out (D) on tail pipe (C) approx. ail pipe (C) approx. ail pipe (C) approx. ail pipe (C) approx.
1-1/2î. Rot 1-1/2î. Rot 1-1/2î. Rot 1-1/2î. Rotate tip to desired position leav- ate tip to desired position leav- ate tip to desired position leav- ate tip to desired position leav­
ing clearance from body ing clearance from body ing clearance from body ing clearance from body. Position clamp . Position clamp . Position clamp . Position clamp
(G) with threads in an upward position. (G) with threads in an upward position. (G) with threads in an upward position. (G) with threads in an upward position.
T
T T Tighten completely with 9/16" deep wall ighten completely with 9/16" deep wall ighten completely with 9/16" deep wall ighten completely with 9/16" deep wall
socket. Note: use anti-seize on threads. socket. Note: use anti-seize on threads. socket. Note: use anti-seize on threads. socket. Note: use anti-seize on threads.
17092 17092 17092 17092
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.
4/17/07