PerTronix JBA Exhaust 40-3009 - Manual

INSTALLATION INSTRUCTIONS
40-3009
GM Silverado / Sierra
1999-2006 4.3/4.8/5.3L
Extended cab / short bed 2/4 wd
TOOLS RECOMMENDED:
TO ST ART :
ratchet
9/16" deep socket
15mm deep socket
pair of channel lock pliers
reciprocating saw or hack saw
rubber mallet
spray lubricant or penetrating oil
anti-seize
prybar
2. Disconnect negative battery cable 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 1"
behind rear muffler hanger.
4. Spray lubricant on front and rear tail
pipe rubber grommet.
INSTALLATION INSTRUCTIONS
T
TO ST ART :
2. Disconnect negative battery cable 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 1"
behind rear muffler hanger.
4. Spray lubricant on front and rear tail
pipe rubber grommet.
INSTALLATION INSTRUCTIONS
T
TO ST ART :
2. Disconnect negative battery cable 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 1"
behind rear muffler hanger.
4. Spray lubricant on front and rear tail
pipe rubber grommet.
INSTALLATION INSTRUCTIONS
T
TO ST ART :
2. Disconnect negative battery cable 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 1"
behind rear muffler hanger.
4. Spray lubricant on front and rear tail
pipe rubber grommet.
5. Using a pair of channel lock pliers,
remove hanger rods from bottom holes of
front and rear tailpipe rubber grommets.
9. With muffler and head pipe properly
supported, using a pair of channel lock
pliers, remove hanger rod from bottom
hole of grommet.
1. Remove and inventory new Evol™
exhaust.
10. Remove muffler and head pipe
assembly.
6. Remove tail pipe assembly from the
rear of vehicle.
11. Install head pipe (A) hanger into
bottom hole of rubber grommet.
15. With the JBA logo to the rear of the
vehicle, slip muffler (B) on head pipe (A).
NOTE:
You may have to tap it with a
rubber mallet.
16. Slip rear muffler hanger (F) over rear
slip joint of muffler (B) and hand tighten at
this time.
17. Position 3" clamp (E) on muffler (B)
and using a 9/16" deep socket, tighten
completely. NOTE: use anti-seize on threads.
26. Using a soft cloth, remove all prints
from turnout tip.
27. Lower vehicle and reattach the
negative battery cable.
28. Run vehicle until exhaust reaches
operating temperature and retighten the
two 15mm flange nuts.
NOTES:
1) All exhaust systems will expand about
1" rearward when exhaust temperature
start to rise.
2) Use Anti-seize on threads of clamps E,
F and G.
12. Install head pipe over studs and install
flange nuts and align flange. using a
15mm socket and ratchet, tighten nuts
completely. NOTE: we recommend using
anti-seize on threads.
13. Install 3" clamp (E) over head pipe (A).
14. Install rear muffler hanger clamp (F)
into the bottom hole of rear muffler
hanger rubber grommet.
8. Spray lubricant on front muffler hanger
grommet.
5. Using a pair of channel lock pliers,
remove hanger rods from bottom holes of
front and rear tailpipe rubber grommets.
9. With muffler and head pipe properly
supported, using a pair of channel lock
pliers, remove hanger rod from bottom
hole of grommet.
1. Remove and inventory new Evol™
exhaust.
10. Remove muffler and head pipe
assembly.
6. Remove tail pipe assembly from the
rear of vehicle.
11. Install head pipe (A) hanger into
bottom hole of rubber grommet.
15. With the JBA logo to the rear of the
vehicle, slip muffler (B) on head pipe (A).
NOTE:
You may have to tap it with a
rubber mallet.
16. Slip rear muffler hanger (F) over rear
slip joint of muffler (B) and hand tighten at
this time.
17. Position 3" clamp (E) on muffler (B)
and using a 9/16" deep socket, tighten
completely. NOTE: use anti-seize on threads.
26. Using a soft cloth, remove all prints
from turnout tip.
27. Lower vehicle and reattach the
negative battery cable.
28. Run vehicle until exhaust reaches
operating temperature and retighten the
two 15mm flange nuts.
NOTES:
1) All exhaust systems will expand about
1" rearward when exhaust temperature
start to rise.
2) Use Anti-seize on threads of clamps E,
F and G.
12. Install head pipe over studs and install
flange nuts and align flange. using a
15mm socket and ratchet, tighten nuts
completely. NOTE: we recommend using
anti-seize on threads.
13. Install 3" clamp (E) over head pipe (A).
14. Install rear muffler hanger clamp (F)
into the bottom hole of rear muffler
hanger rubber grommet.
8. Spray lubricant on front muffler hanger
grommet.
5. Using a pair of channel lock pliers,
remove hanger rods from bottom holes of
front and rear tailpipe rubber grommets.
9. With muffler and head pipe properly
supported, using a pair of channel lock
pliers, remove hanger rod from bottom
hole of grommet.
1. Remove and inventory new Evol™
exhaust.
10. Remove muffler and head pipe
assembly.
6. Remove tail pipe assembly from the
rear of vehicle.
11. Install head pipe (A) hanger into
bottom hole of rubber grommet.
15. With the JBA logo to the rear of the
vehicle, slip muffler (B) on head pipe (A).
NOTE:
You may have to tap it with a
rubber mallet.
16. Slip rear muffler hanger (F) over rear
slip joint of muffler (B) and hand tighten at
this time.
17. Position 3" clamp (E) on muffler (B)
and using a 9/16" deep socket, tighten
completely. NOTE: use anti-seize on threads.
26. Using a soft cloth, remove all prints
from turnout tip.
27. Lower vehicle and reattach the
negative battery cable.
28. Run vehicle until exhaust reaches
operating temperature and retighten the
two 15mm flange nuts.
NOTES:
1) All exhaust systems will expand about
1" rearward when exhaust temperature
start to rise.
2) Use Anti-seize on threads of clamps E,
F and G.
12. Install head pipe over studs and install
flange nuts and align flange. using a
15mm socket and ratchet, tighten nuts
completely. NOTE: we recommend using
anti-seize on threads.
13. Install 3" clamp (E) over head pipe (A).
14. Install rear muffler hanger clamp (F)
into the bottom hole of rear muffler
hanger rubber grommet.
8. Spray lubricant on front muffler hanger
grommet.
5. Using a pair of channel lock pliers,
remove hanger rods from bottom holes of
front and rear tailpipe rubber grommets.
9. With muffler and head pipe properly
supported, using a pair of channel lock
pliers, remove hanger rod from bottom
hole of grommet.
1. Remove and inventory new
exhaust.
10. Remove muffler and head pipe
assembly.
6. Remove tail pipe assembly from the
rear of vehicle.
11. Install head pipe (A) hanger into
bottom hole of rubber grommet.
15. With the JBA logo to the rear of the
vehicle, slip muffler (B) on head pipe (A).
NOTE:
You may have to tap it with a
rubber mallet.
16. Slip rear muffler hanger (F) over rear
slip joint of muffler (B) and hand tighten at
this time.
17. Position 3" clamp (E) on muffler (B)
and using a 9/16" deep socket, tighten
completely. NOTE: use anti-seize on threads.
26. Using a soft cloth, remove all prints
from turnout tip.
27. Lower vehicle and reattach the
negative battery cable.
28. Run vehicle until exhaust reaches
operating temperature and retighten the
two 15mm flange nuts.
NOTES:
1) All exhaust systems will expand about
1" rearward when exhaust temperature
start to rise.
2) Use Anti-seize on threads of clamps E,
F and G.
12. Install head pipe over studs and install
flange nuts and align flange. using a
15mm socket and ratchet, tighten nuts
completely. NOTE: we recommend using
anti-seize on threads.
13. Install 3" clamp (E) over head pipe (A).
14. Install rear muffler hanger clamp (F)
into the bottom hole of rear muffler
hanger rubber grommet.
8. Spray lubricant on front muffler hanger
grommet.
7. Using a 15mm socket and ratchet,
remove flange nuts from head pipe.
7. Using a 15mm socket and ratchet,
remove flange nuts from head pipe.
7. Using a 15mm socket and ratchet,
remove flange nuts from head pipe.
7. Using a 15mm socket and ratchet,
remove flange nuts from head pipe.
18. Install tail pipe (C) into rear slip joint
on muffler (B). NOTE: tail pipe (C)
should be installed with the hanger to
the rear of the vehicle.
18. Install tail pipe (C) into rear slip joint
on muffler (B). NOTE: tail pipe (C)
should be installed with the hanger to
the rear of the vehicle.
18. Install tail pipe (C) into rear slip joint
on muffler (B). NOTE: tail pipe (C)
should be installed with the hanger to
the rear of the vehicle.
18. Install tail pipe (C) into rear slip joint
on muffler (B). NOTE: tail pipe (C)
should be installed with the hanger to
the rear of the vehicle.
19. Install tail pipe (C) hanger rod into
bottom hole of rear rubber hanger
grommet.
19. Install tail pipe (C) hanger rod into
bottom hole of rear rubber hanger
grommet.
19. Install tail pipe (C) hanger rod into
bottom hole of rear rubber hanger
grommet.
19. Install tail pipe (C) hanger rod into
bottom hole of rear rubber hanger
grommet.
20. With tail pipe (C) aligned to desired
position, using a 9/16" deep socket,
tighten nuts on rear muffler hanger (F)
completely.
NOTE:
use anti-seize on threads.
21. Install 3" clamp (G) over end of tail
pipe (C).
22. Install turnout (D) slip joint over end
of tail pipe (C).
23. Position turnout (D) to desired position.
25. After installation, it is recommended
that all clamps be retightened and joints
be tack welded in three spot.
24. Position 3" clamp (I) over turnout (D)
slip joint and tighten completely using a
9/16" deep socket. NOTE: use anti-seize
on threads.
20. With tail pipe (C) aligned to desired
position, using a 9/16" deep socket,
tighten nuts on rear muffler hanger (F)
completely.
NOTE:
use anti-seize on threads.
21. Install 3" clamp (G) over end of tail
pipe (C).
22. Install turnout (D) slip joint over end
of tail pipe (C).
23. Position turnout (D) to desired position.
25. After installation, it is recommended
that all clamps be retightened and joints
be tack welded in three spot.
24. Position 3" clamp (I) over turnout (D)
slip joint and tighten completely using a
9/16" deep socket. NOTE: use anti-seize
on threads.
20. With tail pipe (C) aligned to desired
position, using a 9/16" deep socket,
tighten nuts on rear muffler hanger (F)
completely.
NOTE:
use anti-seize on threads.
21. Install 3" clamp (G) over end of tail
pipe (C).
22. Install turnout (D) slip joint over end
of tail pipe (C).
23. Position turnout (D) to desired position.
25. After installation, it is recommended
that all clamps be retightened and joints
be tack welded in three spot.
24. Position 3" clamp (I) over turnout (D)
slip joint and tighten completely using a
9/16" deep socket. NOTE: use anti-seize
on threads.
20. With tail pipe (C) aligned to desired
position, using a 9/16" deep socket,
tighten nuts on rear muffler hanger (F)
completely.
NOTE:
use anti-seize on threads.
21. Install 3" clamp (G) over end of tail
pipe (C).
22. Install turnout (D) slip joint over end
of tail pipe (C).
23. Position turnout (D) to desired position.
25. After installation, it is recommended
that all clamps be retightened and joints
be tack welded in three spot.
24. Position 3" clamp (I) over turnout (D)
slip joint and tighten completely using a
9/16" deep socket. NOTE: use anti-seize
on threads.
We recommend taking the truck to a muffler shop and having all slip connections tack welded.
Part s List
A. Head pipe 1
B. Muffler 24" 1
C. Tail pipe 1
D. Turn out 1
E. Front muffler clamp 3" 1
F. Rear muffler clamp/hanger 3" 1
G. Turn out clamp/hanger 3" 1
**Installation recommendation: JBA recommends in most cases that the vehicle be taken to a reputable exhaust shop.
We recommend taking the truck to a muffler shop and having all slip connections tack welded.
.
.
We recommend taking the truck to a muffler shop and having all slip connections tack welded.
.
.
We recommend taking the truck to a muffler shop and having all slip connections tack welded.
.
E F
C
B
G
D
17024
A