PerTronix JBA Exhaust 40-2522 - Manual

INSTALLATION INSTRUCTIONS
40-2522
1999-00 Ford F-150 Ext/Std 2/4 WD
V8-4.6L, V8- 5.4L
1998 5.4L V8
TOOLS RECOMMENDED:
TO START:
ratchet
9/16 deep socket
15mm socket
pair of channel lock pliers
reciprocating saw or hack
saw
8mm wrench rubber mallet
spray lubricant or penetrating
oil
prybar
impact wrench
anti-seize
2. Disconnect negative battery cable with
8 mm wrench and allow vehicle exhaust
to cool.
3. With vehicle raised and properly sup-
ported, using a reciprocating saw or hack
saw, cut the tail pipe approximately 3î
behind muffler.
4. Spray lubricant on lower rubber hanger
grommet on rear section of tail pipe.
INSTALLATION INSTRUCTIONS
1999-00 Ford F-150 Ext/Std 2/4 WD
V8-4.6L, V8- 5.4L
1998 5.4L V8
TOOLS RECOMMENDED:
TO START:
ratchet
9/16 deep socket
15mm socket
pair of channel lock pliers
reciprocating saw or hack
saw
8mm wrench rubber mallet
spray lubricant or penetrating
oil
prybar
impact wrench
anti-seize
2. Disconnect negative battery cable with
8 mm wrench and allow vehicle exhaust
to cool.
3. With vehicle raised and properly sup-
ported, using a reciprocating saw or hack
saw, cut the tail pipe approximately 3î
behind muffler.
4. Spray lubricant on lower rubber hanger
grommet on rear section of tail pipe.
INSTALLATION INSTRUCTIONS
1999-00 Ford F-150 Ext/Std 2/4 WD
V8-4.6L, V8- 5.4L
1998 5.4L V8
TOOLS RECOMMENDED:
TO START:
ratchet
9/16 deep socket
15mm socket
pair of channel lock pliers
reciprocating saw or hack
saw
8mm wrench rubber mallet
spray lubricant or penetrating
oil
prybar
impact wrench
anti-seize
2. Disconnect negative battery cable with
8 mm wrench and allow vehicle exhaust
to cool.
3. With vehicle raised and properly sup-
ported, using a reciprocating saw or hack
saw, cut the tail pipe approximately 3î
behind muffler.
4. Spray lubricant on lower rubber hanger
grommet on rear section of tail pipe.
INSTALLATION INSTRUCTIONS
1999-00 Ford F-150 Ext/Std 2/4 WD
V8-4.6L, V8- 5.4L
1998 5.4L V8
TOOLS RECOMMENDED:
TO START:
ratchet
9/16 deep socket
15mm socket
pair of channel lock pliers
reciprocating saw or hack
saw
8mm wrench rubber mallet
spray lubricant or penetrating
oil
prybar
impact wrench
anti-seize
2. Disconnect negative battery cable with
8 mm wrench and allow vehicle exhaust
to cool.
3. With vehicle raised and properly sup-
ported, using a reciprocating saw or hack
saw, cut the tail pipe approximately 3î
behind muffler.
4. Spray lubricant on lower rubber hanger
grommet on rear section of tail pipe.
5. Using channel lock pliers, remove rear
tail pipe hanger rod from lower hole of
rubber grommet.
9. Lubricate front muffler clamp bolts and
using a 15 mm socket, loosen and
remove clamp.
1. Remove and inventory new JBA
exhaust.
10. Using some form of force, or heat,
disengage and remove muffler.
Note: Do Not Damage stock headpipe.
11. Install JBA head pipe (A), aligning
notch with locating pin.
Note: Make sure
pin is bottomed out in notch.
6. Remove tail pipe assembly from the
rear of vehicle.
7. Spray lubricant on all holes of muffler
hanger grommets.
16. Put anti-seize on threads of 2"
clamp (E) and install on front of head-
pipe with 9/16" deep wall socket.
Tightening completely.
Note: make sure clamp is on the rear
side of pin as close as possible.
18. Install tail pipe (C) from rear of vehicle,
and slip into muffler.
Note: make sure that
the end of the tail pipe with the hanger is
at the rear of the vehicle.
20. Tighten 3" clamp/hanger (G) com-
pletely with 9/16" deep socket.
NOTE: use anti-seize on threads.
23. Reattach the negative battery cable.
24. After installation, it is recommended
that all clamps be retightened and joints
be tack welded in 3 spots
22. Rotate turn out (D) to desired posi-
tion, leaving clearance from body.
Position 3" clamp (H) over slip joint and
tighten completely using 9/16" deep
socket.
NOTE: use anti-seize on threads.
NOTES:
1) It may be necessary to loosen and
realign the spare tire for proper clear-
ance.
2) All exhaust systems will expand about
1î rearward when exhaust temperature
start to rise.
3) Use Anti-seize on threads of clamps.
13. Install muffler.
14. Slip muffler hanger (G) over end of
muffler (B) and hand tighten only.
15. Rotate head pipe (A) to desired posi-
tion.
12. Reinstall two rubber grommets to
stock hangers and install muffler hang-
er (G) thru lower holes of grommet.
Note: longer end of hanger is to go on
drivers side, looking from rear.
8. Using a pair of channel lock pliers,
remove rubber grommets completely and
save.
They will be reinstalled .
5. Using channel lock pliers, remove rear
tail pipe hanger rod from lower hole of
rubber grommet.
9. Lubricate front muffler clamp bolts and
using a 15 mm socket, loosen and
remove clamp.
1. Remove and inventory new JBA
exhaust.
10. Using some form of force, or heat,
disengage and remove muffler.
Note: Do Not Damage stock headpipe.
11. Install JBA head pipe (A), aligning
notch with locating pin.
Note: Make sure
pin is bottomed out in notch.
6. Remove tail pipe assembly from the
rear of vehicle.
7. Spray lubricant on all holes of muffler
hanger grommets.
16. Put anti-seize on threads of 2"
clamp (E) and install on front of head-
pipe with 9/16" deep wall socket.
Tightening completely.
Note: make sure clamp is on the rear
side of pin as close as possible.
18. Install tail pipe (C) from rear of vehicle,
and slip into muffler.
Note: make sure that
the end of the tail pipe with the hanger is
at the rear of the vehicle.
20. Tighten 3" clamp/hanger (G) com-
pletely with 9/16" deep socket.
NOTE: use anti-seize on threads.
23. Reattach the negative battery cable.
24. After installation, it is recommended
that all clamps be retightened and joints
be tack welded in 3 spots
22. Rotate turn out (D) to desired posi-
tion, leaving clearance from body.
Position 3" clamp (H) over slip joint and
tighten completely using 9/16" deep
socket.
NOTE: use anti-seize on threads.
NOTES:
1) It may be necessary to loosen and
realign the spare tire for proper clear-
ance.
2) All exhaust systems will expand about
1î rearward when exhaust temperature
start to rise.
3) Use Anti-seize on threads of clamps.
14. Slip muffler hanger (G) over end of
muffler (B) and hand tighten only.
15. Rotate head pipe (A) to desired posi-
tion.
12. Reinstall two rubber grommets to
stock hangers and install muffler hang-
er (G) thru lower holes of grommet.
Note: longer end of hanger is to go on
drivers side, looking from rear.
8. Using a pair of channel lock pliers,
remove rubber grommets completely and
save.
They will be reinstalled .
5. Using channel lock pliers, remove rear
tail pipe hanger rod from lower hole of
rubber grommet.
9. Lubricate front muffler clamp bolts and
using a 15 mm socket, loosen and
remove clamp.
1. Remove and inventory new JBA
exhaust.
10. Using some form of force, or heat,
disengage and remove muffler.
Note: Do Not Damage stock headpipe.
11. Install JBA head pipe (A), aligning
notch with locating pin.
Note: Make sure
pin is bottomed out in notch.
6. Remove tail pipe assembly from the
rear of vehicle.
7. Spray lubricant on all holes of muffler
hanger grommets.
16. Put anti-seize on threads of 2"
clamp (E) and install on front of head-
pipe with 9/16" deep wall socket.
Tightening completely.
Note: make sure clamp is on the rear
side of pin as close as possible.
18. Install tail pipe (C) from rear of vehicle,
and slip into muffler.
Note: make sure that
the end of the tail pipe with the hanger is
at the rear of the vehicle.
20. Tighten 3" clamp/hanger (G) com-
pletely with 9/16" deep socket.
NOTE: use anti-seize on threads.
23. Reattach the negative battery cable.
24. After installation, it is recommended
that all clamps be retightened and joints
be tack welded in 3 spots
22. Rotate turn out (D) to desired posi-
tion, leaving clearance from body.
Position 3" clamp (H) over slip joint and
tighten completely using 9/16" deep
socket.
NOTE: use anti-seize on threads.
NOTES:
1) It may be necessary to loosen and
realign the spare tire for proper clear-
ance.
2) All exhaust systems will expand about
1î rearward when exhaust temperature
start to rise.
3) Use Anti-seize on threads of clamps.
14. Slip muffler hanger (G) over end of
muffler (B) and hand tighten only.
15. Rotate head pipe (A) to desired posi-
tion.
12. Reinstall two rubber grommets to
stock hangers and install muffler hang-
er (G) thru lower holes of grommet.
Note: longer end of hanger is to go on
drivers side, looking from rear.
8. Using a pair of channel lock pliers,
remove rubber grommets completely and
save.
They will be reinstalled .
5. Using channel lock pliers, remove rear
tail pipe hanger rod from lower hole of
rubber grommet.
9. Lubricate front muffler clamp bolts and
using a 15 mm socket, loosen and
remove clamp.
1. Remove and inventory new JBA
exhaust.
10. Using some form of force, or heat,
disengage and remove muffler.
Note: Do Not Damage stock headpipe.
11. Install JBA head pipe (A), aligning
notch with locating pin.
Note: Make sure
pin is bottomed out in notch.
6. Remove tail pipe assembly from the
rear of vehicle.
7. Spray lubricant on all holes of muffler
hanger grommets.
16. Put anti-seize on threads of 2"
clamp (E) and install on front of head-
pipe with 9/16" deep wall socket.
Tightening completely.
Note: make sure clamp is on the rear
side of pin as close as possible.
18. Install tail pipe (C) from rear of vehicle,
and slip into muffler.
Note: make sure that
the end of the tail pipe with the hanger is
at the rear of the vehicle.
20. Tighten 3" clamp/hanger (G) com-
pletely with 9/16" deep socket.
NOTE: use anti-seize on threads.
23. Reattach the negative battery cable.
24. After installation, it is recommended
that all clamps be retightened and joints
be tack welded in 3 spots
22. Rotate turn out (D) to desired posi-
tion, leaving clearance from body.
Position 3" clamp (H) over slip joint and
tighten completely using 9/16" deep
socket.
NOTE: use anti-seize on threads.
NOTES:
1) It may be necessary to loosen and
realign the spare tire for proper clear-
ance.
2) All exhaust systems will expand about
1î rearward when exhaust temperature
start to rise.
3) Use Anti-seize on threads of clamps.
14. Slip muffler hanger (G) over end of
muffler (B) and hand tighten only.
15. Rotate head pipe (A) to desired posi-
tion.
12. Reinstall two rubber grommets to
stock hangers and install muffler hang-
er (G) thru lower holes of grommet.
Note: longer end of hanger is to go on
drivers side, looking from rear.
8. Using a pair of channel lock pliers,
remove rubber grommets completely and
save.
They will be reinstalled .
17. Put anti-seize on 3" clamp (F) and
install to front slip of muffler. Position
clamp 1/2" from lip and tighten completely
with 9/16" socket. 17. Put anti-seize on 3" clamp (F) and
install to front slip of muffler. Position
clamp 1/2" from lip and tighten completely
with 9/16" socket. 17. Put anti-seize on 3" clamp (F) and
install to front slip of muffler. Position
clamp 1/2" from lip and tighten completely
with 9/16" socket. 17. Put anti-seize on 3" clamp (F) and
install to front slip of muffler. Position
clamp 1/2" from lip and tighten completely
with 9/16" socket.
21. Slip 3" clamp (H) over end of tail pipe (C).
Install turn out (D) over end of tail pipe (C). 21. Slip 3" clamp (H) over end of tail pipe (C).
Install turn out (D) over end of tail pipe (C). 21. Slip 3" clamp (H) over end of tail pipe (C).
Install turn out (D) over end of tail pipe (C). 21. Slip 3" clamp (H) over end of tail pipe (C).
Install turn out (D) over end of tail pipe (C).
19. Install rear tail pipe hanger into
lower hole of rubber grommet. Rotate
tail pipe (C) to align rear hanger rod. 19. Install rear tail pipe hanger into
lower hole of rubber grommet. Rotate
tail pipe (C) to align rear hanger rod. 19. Install rear tail pipe hanger into
lower hole of rubber grommet. Rotate
tail pipe (C) to align rear hanger rod. 19. Install rear tail pipe hanger into
lower hole of rubber grommet. Rotate
tail pipe (C) to align rear hanger rod.
We recommend taking the truck to a muffler shop and having all slip connections tack welded.
A. Head pipe 1
B. 24" muffler 1
C. Tail pipe 1
D. Turn out 1
E. 2-1/2" clamp 1
F. 3" clamp 1
G. 3" muffler clamp/hanger 1
H. 3" tail pipe clamp 1
**Inst allation recommendation:
JBA recommends in most cases that the vehicle be taken to a reputable exhaust shop.
6.13.06
Parts List
We recommend taking the truck to a muffler shop and having all slip connections tack welded.
A. Head pipe 1
B. 24" muffler 1
C. Tail pipe 1
D. Turn out 1
E. 2-1/2" clamp 1
F. 3" clamp 1
G. 3" muffler clamp/hanger 1
H. 3" tail pipe clamp 1
**Inst allation recommendation:
JBA recommends in most cases that the vehicle be taken to a reputable exhaust shop.
Parts List
We recommend taking the truck to a muffler shop and having all slip connections tack welded.
A. Head pipe 1
B. 24" muffler 1
C. Tail pipe 1
D. Turn out 1
E. 2-1/2" clamp 1
F. 3" clamp 1
G. 3" muffler clamp/hanger 1
H. 3" tail pipe clamp 1
**Inst allation recommendation:
JBA recommends in most cases that the vehicle be taken to a reputable exhaust shop.
Parts List
We recommend taking the truck to a muffler shop and having all slip connections tack welded.
A. Head pipe 1
B. 24" muffler 1
C. Tail pipe 1
D. Turn out 1
E. 2-1/2" clamp 1
F. 3" clamp 1
G. 3" muffler clamp/hanger 1
H. 3" tail pipe clamp 1
**Inst allation recommendation:
JBA recommends in most cases that the vehicle be taken to a reputable exhaust shop.
Parts List
D
H
B
E
F
A
C
G
D
H
B
E
F
A
C
G
D
H
B
E
F
A
C
G
D
H
B
E
F
A
C
G