PerTronix JBA Exhaust 40-2521 - 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 JBA recommends in most cases that the vehicle be taken to a reputable JBA recommends in most cases that the vehicle be taken to a reputable JBA recommends in most cases that the vehicle be taken to a reputable
40-2521
2001 Ford F-150 Super Crew
4.6L, 5.4L 2/4 WD
T OOLS RECOMMENDED:
ratchet
9/16 deep socket
15mm deep socket
channel lock pliers
8mm wrench
rubber mallet
spray lubricant or penetrating oil
pry bar
reciprocating saw or hack saw
2001 Ford F-150 Super Crew
4.6L, 5.4L 2/4 WD
T OOLS RECOMMENDED:
ratchet
9/16 deep socket
15mm deep socket
channel lock pliers
8mm wrench
rubber mallet
spray lubricant or penetrating oil
pry bar
reciprocating saw or hack saw
2001 Ford F-150 Super Crew
4.6L, 5.4L 2/4 WD
T OOLS RECOMMENDED:
ratchet
9/16 deep socket
15mm deep socket
channel lock pliers
8mm wrench
rubber mallet
spray lubricant or penetrating oil
pry bar
reciprocating saw or hack saw
2001 Ford F-150 Super Crew
4.6L, 5.4L 2/4 WD
T OOLS RECOMMENDED:
ratchet
9/16 deep socket
15mm deep socket
channel lock pliers
8mm wrench
rubber mallet
spray lubricant or penetrating oil
pry bar
reciprocating saw or hack saw
A. Head pipe 1
B. Muffler 1
C. Tail pipe 1
D. Turn out 1
E. 2-1/2" clamp 1
F. 3" clamp 1
G. 3" clamp/hanger 1
H. 3" clamp 1
A. Head pipe 1
B. Muffler 1
C. Tail pipe 1
D. Turn out 1
E. 2-1/2" clamp 1
F. 3" clamp 1
G. 3" clamp/hanger 1
H. 3" clamp 1
A. Head pipe 1
B. Muffler 1
C. Tail pipe 1
D. Turn out 1
E. 2-1/2" clamp 1
F. 3" clamp 1
G. 3" clamp/hanger 1
H. 3" clamp 1
A. Head pipe 1
B. Muffler 1
C. Tail pipe 1
D. Turn out 1
E. 2-1/2" clamp 1
F. 3" clamp 1
G. 3" clamp/hanger 1
H. 3" clamp 1
B
A
D
E
C
F G H
Part s List
B
A
D
E
C
F G H
Part s List
B
A
D
E
C
F G H
Part s List
B
A
D
E
C
F G H
Part s List
anti-seize anti-seize anti-seize anti-seize
T T T T O O O O ST ST ST ST ART ART ART ART ::::
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 Evol 1. Remove and inventory new Evol 1. Remove and inventory new Evol 1. Remove and inventory new Evol
exhaust.
exhaust. exhaust. exhaust.
8. Using some form of heat and force, 8. Using some form of heat and force, 8. Using some form of heat and force, 8. Using some form of heat and force,
remove muf
remove muf remove muf remove muffler assembly t fler assembly t fler assembly t fler assembly taking care not aking care not aking care not aking care not
to damage front head pipe. to damage front head pipe. to damage front head pipe. to damage front head pipe.
12. Slip muf 12. Slip muf 12. Slip muf 12. 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
muf muf muf muffler (B)) and hand tighten only at fler (B)) and hand tighten only at fler (B)) and hand tighten only at fler (B)) and hand tighten only at
this time. this time. this time. this time.
17. With t 17. With t 17. With t 17. With tail pipe properly aligned, tighten ail pipe properly aligned, tighten ail pipe properly aligned, tighten ail pipe properly aligned, tighten
rear muf rear muf rear muf rear muffler clamp/hanger (G) completely fler clamp/hanger (G) completely fler clamp/hanger (G) completely fler clamp/hanger (G) completely
3. With vehicle raised and properly 3. With vehicle raised and properly 3. With vehicle raised and properly 3. With vehicle raised and properly
supported, using a reciprocating saw
supported, using a reciprocating saw supported, using a reciprocating saw supported, using a reciprocating saw
or hack saw
or hack saw or hack saw or hack saw, cut the t , cut the t , cut the t , cut the tail pipe approx. ail pipe approx. ail pipe approx. ail pipe approx.
3î behind muf 3î behind muf 3î behind muf 3î behind muffler fler fler fler. See notes #1 . See notes #1 . See notes #1 . See notes #1
with 9/16" deep wall socket. with 9/16" deep wall socket. with 9/16" deep wall socket. with 9/16" deep wall socket. NOTE: NOTE: NOTE: NOTE: Use Use Use Use
anti-seize on all threads of clamp. See anti-seize on all threads of clamp. See anti-seize on all threads of clamp. See anti-seize on all threads of clamp. See
note #2.
note #2. note #2. note #2.
4. S 4. S 4. S 4. Spray lube on rear t pray lube on rear t pray lube on rear t pray lube on rear tail pipe hanger rod ail pipe hanger rod ail pipe hanger rod ail pipe hanger rod
and remove from lower hole in rubber and remove from lower hole in rubber and remove from lower hole in rubber and remove from lower hole in rubber
grommet using channel lock pliers.
grommet using channel lock pliers. grommet using channel lock pliers. grommet using channel lock pliers.
5. Remove t 5. Remove t 5. Remove t 5. Remove tail pipe assembly from ail pipe assembly from ail pipe assembly from ail pipe assembly from
rear of vehicle. rear of vehicle. rear of vehicle. rear of vehicle.
9. Inst 9. Inst 9. Inst 9. Install head pipe (A), aligning notch all head pipe (A), aligning notch all head pipe (A), aligning notch all head pipe (A), aligning notch
with locating pin. with locating pin. with locating pin. with locating pin. Y Y Y You may have to t ou may have to t ou may have to t ou may have to tap it ap it ap it ap it
on using a rubber mallet. on using a rubber mallet. on using a rubber mallet. on using a rubber mallet.
13. Inst 13. Inst 13. Inst 13. Install 2-1/2" clamp (E) over front slip all 2-1/2" clamp (E) over front slip all 2-1/2" clamp (E) over front slip all 2-1/2" clamp (E) over front slip
joint on head pipe (A). Position so clamp joint on head pipe (A). Position so clamp joint on head pipe (A). Position so clamp joint on head pipe (A). Position so clamp
is on rear side of locating pen as close as
is on rear side of locating pen as close as is on rear side of locating pen as close as is on rear side of locating pen as close as
possible and tighten completely using a
possible and tighten completely using a possible and tighten completely using a possible and tighten completely using a
9/16" deep wall socket.
9/16" deep wall socket. 9/16" deep wall socket. 9/16" deep wall socket. NOTE: NOTE: NOTE: NOTE: Use anti- Use anti- Use anti- Use anti­
seize on threads of clamp. See note #2 seize on threads of clamp. See note #2 seize on threads of clamp. See note #2 seize on threads of clamp. See note #2
14. Inst 14. Inst 14. Inst 14. Install 3" clamp (F) over front muf all 3" clamp (F) over front muf all 3" clamp (F) over front muf all 3" clamp (F) over front muffler fler fler fler
slip joint and position 1/4" from lip. slip joint and position 1/4" from lip. slip joint and position 1/4" from lip. slip joint and position 1/4" from lip.
T
T T Tighten completely with 9/16" deep ighten completely with 9/16" deep ighten completely with 9/16" deep ighten completely with 9/16" deep
socket. socket. socket. socket. NOTE: NOTE: NOTE: NOTE: Use anti-seize on Use anti-seize on Use anti-seize on Use anti-seize on
threads of clamp. See note #2. threads of clamp. See note #2. threads of clamp. See note #2. threads of clamp. See note #2.
18. Inst 18. Inst 18. Inst 18. 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 ail pipe ail pipe ail pipe
(C) and rot (C) and rot (C) and rot (C) and rotate to desired position leaving ate to desired position leaving ate to desired position leaving ate to desired position leaving
clearance from body clearance from body clearance from body clearance from body....
6. With muf 6. With muf 6. With muf 6. With muffler supported, spray lubricant fler supported, spray lubricant fler supported, spray lubricant fler supported, spray lubricant
on rear muf on rear muf on rear muf on rear muffler hanger rods and remove fler hanger rods and remove fler hanger rods and remove fler hanger rods and remove
from lower holes in rubber grommet from lower holes in rubber grommet from lower holes in rubber grommet from lower holes in rubber grommets s s s
using channel lock pliers. using channel lock pliers. using channel lock pliers. using channel lock pliers.
7. 7. 7. 7. S S S Spray lubricant on front muf pray lubricant on front muf pray lubricant on front muf pray lubricant on front muffler clamp fler clamp fler clamp fler clamp
and remove using a 15mm socket and remove using a 15mm socket and remove using a 15mm socket and remove using a 15mm socket
1 1 1 11. Inst 1. Inst 1. Inst 1. Install muf all muf all muf all muffler (B) with JBA logo fler (B) with JBA logo fler (B) with JBA logo fler (B) with JBA logo
towards rear of vehicle. towards rear of vehicle. towards rear of vehicle. towards rear of vehicle.
10. Inst 10. Inst 10. Inst 10. Install rear 3" muf all rear 3" muf all rear 3" muf all rear 3" muffler clamp/hanger fler clamp/hanger fler clamp/hanger fler clamp/hanger
(G) through lower holes in rubber grom- (G) through lower holes in rubber grom- (G) through lower holes in rubber grom- (G) through lower holes in rubber grom­
met
met met mets with longer rod towards driver s with longer rod towards driver s with longer rod towards driver s with longer rod towards driveríííís side. s side. s side. s side.
15. Inst 15. Inst 15. Inst 15. Install t all t all t all tail pipe (C) from rear of vehi- ail pipe (C) from rear of vehi- ail pipe (C) from rear of vehi- ail pipe (C) from rear of vehi­
cle and slip into rear of muf cle and slip into rear of muf cle and slip into rear of muf cle and slip into rear of muffler (B). fler (B). fler (B). fler (B).
NOTE: NOTE: NOTE: NOTE: Make sure that the end of the Make sure that the end of the Make sure that the end of the Make sure that the end of the
ttttail pipe with the hanger rod is at the ail pipe with the hanger rod is at the ail pipe with the hanger rod is at the ail pipe with the hanger rod is at the
rear of vehicle. rear of vehicle. rear of vehicle. rear of vehicle.
16. Inst 16. Inst 16. Inst 16. Install rear t all rear t all rear t all rear tail pipe hanger into lower ail pipe hanger into lower ail pipe hanger into lower ail pipe hanger into lower
hole of rubber grommet. Rot hole of rubber grommet. Rot hole of rubber grommet. Rot hole of rubber grommet. Rotate t ate t ate t ate tail pipe ail pipe ail pipe ail pipe
(C) to align rear hanger rod. (C) to align rear hanger rod. (C) to align rear hanger rod. (C) to align rear hanger rod.
20. Retighten all clamp 20. Retighten all clamp 20. Retighten all clamp 20. Retighten all clamps and t s and t s and t s and tack weld all ack weld all ack weld all ack weld all
slip joint slip joint slip joint slip joints. s. s. s.
21. Lower vehicle and reatt 21. Lower vehicle and reatt 21. Lower vehicle and reatt 21. Lower vehicle and reattach the ach the ach the ach the
negative battery cable. negative battery cable. negative battery cable. negative battery cable.
NOTES: NOTES: NOTES: NOTES:
1. 1. 1. 1. If vehicle is raised with proper vehicle If vehicle is raised with proper vehicle If vehicle is raised with proper vehicle If vehicle is raised with proper vehicle
lif lif lif lift, step #3 can be eliminated and stock t, step #3 can be eliminated and stock t, step #3 can be eliminated and stock t, step #3 can be eliminated and stock
exhaust can be removed in one piece exhaust can be removed in one piece exhaust can be removed in one piece exhaust can be removed in one piece
2. 2. 2. 2. If anti seize is not used on threads of If anti seize is not used on threads of If anti seize is not used on threads of If anti seize is not used on threads of
clamp clamp clamp clamps before tightening, the nut's will s before tightening, the nut's will s before tightening, the nut's will s before tightening, the nut's will
gall, gall, gall, gall, and clamp rod will break. and clamp rod will break. and clamp rod will break. and clamp rod will break.
19. Inst 19. Inst 19. Inst 19. Install 3" clamp (H) over turn out slip all 3" clamp (H) over turn out slip all 3" clamp (H) over turn out slip all 3" clamp (H) over turn out slip
joint and position 1/4î from lip. joint and position 1/4î from lip. joint and position 1/4î from lip. joint and position 1/4î from lip. T T T Tighten ighten ighten ighten
completely using 9/16" deep socket. completely using 9/16" deep socket. completely using 9/16" deep socket. completely using 9/16" deep socket.
NOTE: NOTE: NOTE: NOTE: Use anti-seize on all threads of Use anti-seize on all threads of Use anti-seize on all threads of Use anti-seize on all threads of
clamp. See note #2 clamp. See note #2 clamp. See note #2 clamp. See note #2
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.