PerTronix JBA Exhaust 40-2623 - Manual

INSTALLATION INSTRUCTIONS
**Ins tallation recommendation: J B A recommends in mos t cas es that the vehicle be taken to a reputable exhaus t s hop.
40-2623
99-04 Mustang GT 4.6L
03-04 Mustang Mach 1 4.6L
2001 Mustang Bullitt 4.6L
Start:
1. Remove and inventory the JBA
Exhaust System.
2. Disconnect the negative battery
cable and allow the exhaust system
to completely cool.
3. With the vehicle raised and
safely supported - cut the tailpipes
behind the factory mufflers.
Parts List:
A.
P/S Intermediate Pipe 1
B. D/S Intermediate Pipe 1
C. JBA Muffler 2
D. P/S Axle Pipe w/ hanger 1
E. D/S Axle Pipe w/ hanger 1
F. P/S Tail pipe w/ tip 1
G. D/S Tail pipe w/ tip 1
H. 2.5" U-bolt clamp 2
I. 2.5" U-bolt clamp w/ hanger 2
J. 2.5" Exhaust flange 2
K. 2.5" Exhaust clamp 2
12/29/05
B
A
C H
K
I
E
D
G
F
J
RECOMMENDED TOOLS:
• pry bar
• ratchet • Sawzall
• 9/16 deep socket • channel lock pliers • spray
lubricant (WD-40)
4. Spray lubricant on to the
exhaust hangers.
5. Using channel lock pliers
remove the hangers form the
rubber isolators.
6. Using a 9/16" deep socket,
remove the nuts attaching the
intermediate pipes to the H-pipe.
8. Install the supplied 2.5" clamps
with hanger (I) in to the rubber
isolators. The long one on the left. 14. Slip the rear clamps with
hangers (I) on to rear neck of
mufflers (C). 19. Position the 2.5" clamps (H)
over the tail pipe/axle pipe
connection with the nuts forward.
21. Align the mufflers (C) to be
even across the front and flat.
20. Align the axle pipes (D & E) to
clear the frame on top, the upper
control arms, and axle. Also check
evenness of tip exit to bumper.
Adjust at tailpipe/muffler
connection. Align and secure with
2.5" exhaust clamps (K).
15. Slip the axle pipes (D & E)
over the axle and in to the JBA
mufflers (C). Mark the pipe to
check the depth of the insertion
and connect the hanger.
7. Remove the mufflers from the
vehicle.
5. Remove the tailpipes from the
vehicle.
9. Slip the supplied flanges (J) on
to the intermediate pipes (A & B).
12. Slip the supplied 2.5" clamp
(H) on the the intermediate pipes
(A & B).
16. Position the 2.5" clamps (H)
over the Muffler/Intermediate
connection.
17. Slip a 2.5" exhaust clamp (K)
on to rear of axle pipes D & E).
18. Slip the tail pipes (F & G)
hangers in to the rear isolators.
19. Connect the axle pipes (D & E)
to the tail pipes (G & F).
13. Install the new JBA mufflers
(C) on to the intermediate pipes (A
& B) with the inlet forward. Mark
the pipe to insure full insertion.
Correct position is approximately
3/4" from the frame rail.
11. Temporarily snug the nuts
attaching the intermediate pipes (A
& B) to the H-pipe.
10. Position the driver side
intermediate pipe (B) on the H-pipe
with the off-set facing up and out
about 30º. On the passenger side
intermediate (A) position the offset
straight up.
22. Check all clamps and
connections for proper fit and
alignment. Double check all clamps
are tightened and that all hangers
are secure in rubber grommets. It is
recommended that after installation
of this system you have all slip
connections tack welded by a muffler
shop.
NOTES:
1.) All exhaust systems expand about 1"
rearward when exhaust temperature
rises.
2.) Use anti-seize on threads of stainless
steel clamps.