PerTronix JBA Exhaust 40-1502 User Manual

Installation instructions, Installation recommendation, T o st art

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INSTALLATION INSTRUCTIONS

40-1502

1991-95 Jeep Wrangler
4.0L L6

T OOLS RECOMMENDED:

T O ST ART :

9/16''deep socket
3/8î ratchet
3/8'' Extension
5/16''allen wrench
13mm socket
21mm socket
21mm combination wrench
channel lock pliers
rubber mallet
anti-seize
spray lubricant or penetrating oil
reciprocating saw or hack saw
pair of channel lock pliers 10î

2. Disconnect negative battery cable and
allow vehicle exhaust to cool.

3. With vehicle raised and properly sup-
ported, remove pan bar over rear axle by
removing two bolts using a 21mm socket
or combination wrench and 5/16'' allen-
wrench.

INSTALLATION INSTRUCTIONS

1991-95 Jeep Wrangler
4.0L L6

T OOLS RECOMMENDED:

T O ST ART :

2. Disconnect negative battery cable and
allow vehicle exhaust to cool.

3. With vehicle raised and properly sup-
ported, remove pan bar over rear axle by
removing two bolts using a 21mm socket
or combination wrench and 5/16'' allen-
wrench.

INSTALLATION INSTRUCTIONS

1991-95 Jeep Wrangler
4.0L L6

T OOLS RECOMMENDED:

T O ST ART :

2. Disconnect negative battery cable and
allow vehicle exhaust to cool.

3. With vehicle raised and properly sup-
ported, remove pan bar over rear axle by
removing two bolts using a 21mm socket
or combination wrench and 5/16'' allen-
wrench.

INSTALLATION INSTRUCTIONS

1991-95 Jeep Wrangler
4.0L L6

T OOLS RECOMMENDED:

T O ST ART :

2. Disconnect negative battery cable and
allow vehicle exhaust to cool.

3. With vehicle raised and properly sup-
ported, remove pan bar over rear axle by
removing two bolts using a 21mm socket
or combination wrench and 5/16'' allen-
wrench.

4. Using a reciprocating saw, cut tail pipe
off 4''behind rear muffler hanger.
See notes #1

15. Install rear muffler clamp/hanger (F)
into lower holes in rubber grommets, with
rods pointing toward passenger side.

1. Remove and inventory new Evol™
exhaust.

5. Remove rear tail pipe hanger using a
13mm socket and extension.

6. Remove tail pipe from rear of vehicle.

23. Check exhaust kit for proper clear-
ances, and tack weld all slip joints in
three spots.

24. Using a soft cloth, remove all prints
from turnout tip.
25. Lower vehicle and reattach the
negative battery cable.

NOTES:

1. If vehicle is lifted with proper vehicle
lift, step #4 can be eliminated. The muf-
fler assembly can be removed in one
piece by removing right rear shock, and
raising right rear frame rail.
2. Due to the possibility of stock catalytic
converter being changed or altered from
stock, JBA has supplied an extra head
pipe with a longer length for customer to
cut at his discretion for a custom fit. First
you must install Evol™ tail pipe (C), rear
muffler clamp/hanger (F), and muffler (B)
and position for proper clearance, to
determine where to cut extra head pipe
supplied.
3. If anti seize is not used on threads of
clamps before tightening, the nut's will
gall, and clamp rod will break.

11. Using some form of heat and force
remove muffler assembly without damag-
ing stock catalytic converter pipe.

12. Install Evol™ head pipe (A), aligning
notch with locating pin. Note: you may
have to tap on with rubber mallet.
See notes #2

13.Install and position 2 º''clamp (D),
over head pipe (A) slip joint and tighten
completely using a 9/16'' deep wall sock-
et.

NOTE:

USE ANTI SEIZE ON

THREADS OF CLAMP

. See notes #3

7. Remove rubber grommet from tail pipe
hanger rod and save, as it will be reused.

8. Remove front muffler clamp using a
15mm socket.

4. Using a reciprocating saw, cut tail pipe
off 4''behind rear muffler hanger.
See notes #1

15. Install rear muffler clamp/hanger (F)
into lower holes in rubber grommets, with
rods pointing toward passenger side.

1. Remove and inventory new Evol™
exhaust.

5. Remove rear tail pipe hanger using a
13mm socket and extension.

6. Remove tail pipe from rear of vehicle.

23. Check exhaust kit for proper clear-
ances, and tack weld all slip joints in
three spots.

24. Using a soft cloth, remove all prints
from turnout tip.
25. Lower vehicle and reattach the
negative battery cable.

NOTES:

11. Using some form of heat and force
remove muffler assembly without damag-
ing stock catalytic converter pipe.

12. Install Evol™ head pipe (A), aligning
notch with locating pin. Note: you may
have to tap on with rubber mallet.
See notes #2

13.Install and position 2 º''clamp (D),
over head pipe (A) slip joint and tighten
completely using a 9/16'' deep wall sock-
et.

NOTE:

USE ANTI SEIZE ON

THREADS OF CLAMP

. See notes #3

7. Remove rubber grommet from tail pipe
hanger rod and save, as it will be reused.

8. Remove front muffler clamp using a
15mm socket.

4. Using a reciprocating saw, cut tail pipe
off 4''behind rear muffler hanger.
See notes #1

15. Install rear muffler clamp/hanger (F)
into lower holes in rubber grommets, with
rods pointing toward passenger side.

1. Remove and inventory new Evol™
exhaust.

5. Remove rear tail pipe hanger using a
13mm socket and extension.

6. Remove tail pipe from rear of vehicle.

23. Check exhaust kit for proper clear-
ances, and tack weld all slip joints in
three spots.

24. Using a soft cloth, remove all prints
from turnout tip.
25. Lower vehicle and reattach the
negative battery cable.

NOTES:

11. Using some form of heat and force
remove muffler assembly without damag-
ing stock catalytic converter pipe.

12. Install Evol™ head pipe (A), aligning
notch with locating pin. Note: you may
have to tap on with rubber mallet.
See notes #2

13.Install and position 2 º''clamp (D),
over head pipe (A) slip joint and tighten
completely using a 9/16'' deep wall sock-
et.

NOTE:

USE ANTI SEIZE ON

THREADS OF CLAMP

. See notes #3

7. Remove rubber grommet from tail pipe
hanger rod and save, as it will be reused.

8. Remove front muffler clamp using a
15mm socket.

4. Using a reciprocating saw, cut tail pipe
off 4''behind rear muffler hanger.
See notes #1

15. Install rear muffler clamp/hanger (F)
into lower holes in rubber grommets, with
rods pointing toward passenger side.

1. Remove and inventory new Evol™
exhaust.

5. Remove rear tail pipe hanger using a
13mm socket and extension.

6. Remove tail pipe from rear of vehicle.

23. Check exhaust kit for proper clear-
ances, and tack weld all slip joints in
three spots.

24. Using a soft cloth, remove all prints
from turnout tip.
25. Lower vehicle and reattach the
negative battery cable.

NOTES:

11. Using some form of heat and force
remove muffler assembly without damag-
ing stock catalytic converter pipe.

12. Install Evol™ head pipe (A), aligning
notch with locating pin. Note: you may
have to tap on with rubber mallet.
See notes #2

13.Install and position 2 º''clamp (D),
over head pipe (A) slip joint and tighten
completely using a 9/16'' deep wall sock-
et.

NOTE:

USE ANTI SEIZE ON

THREADS OF CLAMP

. See notes #3

7. Remove rubber grommet from tail pipe
hanger rod and save, as it will be reused.

8. Remove front muffler clamp using a
15mm socket.

9. Spray lube on two rear muffler hanger
rod rubber grommets.

10. Support muffler and remove two rear
muffler hangers from rubber grommets
using channel lock pliers.

14.Install muffler (B) with offset toward
rear and inward.

16. Position rear muffler clamp/hanger
(F),over rear muf

fler slip joint and hand

tighten only at this time.

17. Install factory rear tail pipe rubber
grommet on rear tail pipe hanger rod.

16. Position rear muffler clamp/hanger
(F),over rear muf

fler slip joint and hand

tighten only at this time.

17. Install factory rear tail pipe rubber
grommet on rear tail pipe hanger rod.

16. Position rear muffler clamp/hanger
(F),over rear muf

fler slip joint and hand

tighten only at this time.

17. Install factory rear tail pipe rubber
grommet on rear tail pipe hanger rod.

16. Position rear muffler clamp/hanger
(F),over rear muf

fler slip joint and hand

tighten only at this time.

17. Install factory rear tail pipe rubber
grommet on rear tail pipe hanger rod.

18.Install tail pipe from rear of vehicle.
Place rubber grommet in holder and slip
tail pipe into rear muffler slip joint 2''.

19. Reassemble rear tail pipe hanger
assembly, and tighten using a 13mm
socket.

20. Position muffler and install 2 ''clamp
(E) over front muffler slip joint.Tighten
completely using a 9/16'' deep wall sock-
et.

NOTE:

USE ANTI SEIZE ON

THREADS OF CLAMP

. See notes #3

20. Position muffler and install 2 ''clamp
(E) over front muffler slip joint.Tighten
completely using a 9/16'' deep wall sock-
et.

NOTE:

USE ANTI SEIZE ON

THREADS OF CLAMP

. See notes #3

20. Position muffler and install 2 ''clamp
(E) over front muffler slip joint.Tighten
completely using a 9/16'' deep wall sock-
et.

NOTE:

USE ANTI SEIZE ON

THREADS OF CLAMP

. See notes #3

20. Position muffler and install 2 ''clamp
(E) over front muffler slip joint.Tighten
completely using a 9/16'' deep wall sock-
et.

NOTE:

USE ANTI SEIZE ON

THREADS OF CLAMP

. See notes #3

21. Reinstall pan bar over rear axle.
Check for proper clearance on tail pipe.

22. Position tail pipe, checking chrome tip
for clearance, and tighten clamp/hanger
(F) completely using a 9/16'' deep wall
socket.

NOTE:

USE ANTI SEIZE ON

THREADS OF CLAMP

. See notes #3

22. Position tail pipe, checking chrome tip
for clearance, and tighten clamp/hanger
(F) completely using a 9/16'' deep wall
socket.

NOTE:

USE ANTI SEIZE ON

THREADS OF CLAMP

. See notes #3

22. Position tail pipe, checking chrome tip
for clearance, and tighten clamp/hanger
(F) completely using a 9/16'' deep wall
socket.

NOTE:

USE ANTI SEIZE ON

THREADS OF CLAMP

. See notes #3

22. Position tail pipe, checking chrome tip
for clearance, and tighten clamp/hanger
(F) completely using a 9/16'' deep wall
socket.

NOTE:

USE ANTI SEIZE ON

THREADS OF CLAMP

. See notes #3

aking the truck to a muffler shop and having all slip connections t

ack welded.

Part s List

A. Head pipe

B. Muffler

C. Tail pipe w/tip

D. 2-1/4î clamp

E. 2-1/2î clamp

. 2-1/2î clamp/hanger

. Extra head pipe

**Installation recommendation:

JBA recommends in most cases that the vehicle be taken to a reputable exhaust shop.

17227

aking the truck to a muffler shop and having all slip connections t

ack welded.

Part s List

A. Head pipe

B. Muffler

C. Tail pipe w/tip

D. 2-1/4î clamp

E. 2-1/2î clamp

. 2-1/2î clamp/hanger

. Extra head pipe

**Installation recommendation:

17227

aking the truck to a muffler shop and having all slip connections t

ack welded.

Part s List

A. Head pipe

B. Muffler

C. Tail pipe w/tip

D. 2-1/4î clamp

E. 2-1/2î clamp

. 2-1/2î clamp/hanger

. Extra head pipe

**Installation recommendation:

17227

aking the truck to a muffler shop and having all slip connections t

ack welded.

Part s List

A. Head pipe

B. Muffler

C. Tail pipe w/tip

D. 2-1/4î clamp

E. 2-1/2î clamp

. 2-1/2î clamp/hanger

. Extra head pipe

**Installation recommendation:

17227

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