PerTronix JBA Exhaust 40-3019 - 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 exhaust shop. JBA recommends in most cases that the vehicle be taken to a reputable exhaust shop. JBA recommends in most cases that the vehicle be taken to a reputable exhaust shop. JBA recommends in most cases that the vehicle be taken to a reputable exhaust shop.
Part Part Part Part s List s List s List s List 40-3019
A. A. A. A. Head pipe Head pipe Head pipe Head pipe 1 1 1 1
B. B. B. B. Muf Muf Muf Muffler 24" fler 24" fler 24" fler 24" 1 1 1 1 96-97 Chevy S-10 pickup 96-97 Chevy S-10 pickup 96-97 Chevy S-10 pickup 96-97 Chevy S-10 pickup
C. C. C. C. T T T Tail pipe ail pipe ail pipe ail pipe 1 1 1 1
96-97 GMC S-15 pickup 96-97 GMC S-15 pickup 96-97 GMC S-15 pickup 96-97 GMC S-15 pickup
D. D. D. D. T T T Turn out urn out urn out urn out 1 1 1 1
E. E. E. E. Front muf Front muf Front muf Front muffler clamp/hanger 3" fler clamp/hanger 3" fler clamp/hanger 3" fler clamp/hanger 3" 1 1 1 1
Ext. Cab/S Ext. Cab/S Ext. Cab/S Ext. Cab/Sttttd. Bed d. Bed d. Bed d. Bed
F F F F.... Rear muf Rear muf Rear muf Rear muffler clamp/hanger 3" fler clamp/hanger 3" fler clamp/hanger 3" fler clamp/hanger 3" 1 1 1 1
G G G G.... T T T Turn out clamp 3" urn out clamp 3" urn out clamp 3" urn out clamp 3" 1 1 1 1 V6-4.3L V6-4.3L V6-4.3L V6-4.3L
E F E F F F E E
G G G G A A A A
T T T T OOLS RECOMMENDED: OOLS RECOMMENDED: OOLS RECOMMENDED: OOLS RECOMMENDED:
reciprocating saw or hack saw reciprocating saw or hack saw reciprocating saw or hack saw reciprocating saw or hack saw
prybar
prybar prybar prybar
rubber mallet
rubber mallet rubber mallet rubber mallet
ratchet
ratchet ratchet ratchet
15mm deep socket
15mm deep socket 15mm deep socket 15mm deep socket
9/16 box wrench and deep socket
9/16 box wrench and deep socket 9/16 box wrench and deep socket 9/16 box wrench and deep socket
p
p p pair of channel lock pliers air of channel lock pliers air of channel lock pliers air of channel lock pliers
anti-seize anti-seize anti-seize anti-seize D D D D
spray lubricant or penetrating oil spray lubricant or penetrating oil spray lubricant or penetrating oil spray lubricant or penetrating oil
imp
imp imp impact wrench act wrench act wrench act wrench
C C C C
T T T T O O O O ST ST ST ST ART ART ART ART ::::
B B B B
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 JBA 1. Remove and inventory new JBA 1. Remove and inventory new JBA 1. Remove and inventory new JBA
exhaust.
exhaust. exhaust. exhaust.
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 hacksaw
or hacksaw or hacksaw or hacksaw, cut the t , cut the t , cut the t , cut the tail pipe approxi- ail pipe approxi- ail pipe approxi- ail pipe approxi­
mately 3" behind rear muf mately 3" behind rear muf mately 3" behind rear muf mately 3" behind rear muffler hanger fler hanger fler hanger fler hanger....
8. With muf 8. With muf 8. With muf 8. With muffler properly supported, fler properly supported, fler properly supported, fler properly supported,
using a p using a p using a p using a pair of channel lock pliers, air of channel lock pliers, air of channel lock pliers, air of channel lock pliers,
remove front and rear muf remove front and rear muf remove front and rear muf remove front and rear muffler hanger fler hanger fler hanger fler hanger
rods from bottom hole of grommet rods from bottom hole of grommet rods from bottom hole of grommet rods from bottom hole of grommets. s. s. s.
14. With muf 14. With muf 14. With muf 14. With muffler (B) in place, arrange fler (B) in place, arrange fler (B) in place, arrange fler (B) in place, arrange
clamp/hanger (E) on slip fit joint about a clamp/hanger (E) on slip fit joint about a clamp/hanger (E) on slip fit joint about a clamp/hanger (E) on slip fit joint about a
1/4î from end of muf
1/4î from end of muf 1/4î from end of muf 1/4î from end of muffler and tighten clamp fler and tighten clamp fler and tighten clamp fler and tighten clamp
completely with 9/16" deep socket. completely with 9/16" deep socket. completely with 9/16" deep socket. completely with 9/16" deep socket.
19. Check all pipes for proper clearance 19. Check all pipes for proper clearance 19. Check all pipes for proper clearance 19. Check all pipes for proper clearance
and tighten clamp/hanger (F).
and tighten clamp/hanger (F). and tighten clamp/hanger (F). and tighten clamp/hanger (F).
NOTE: NOTE: NOTE: NOTE: use anti seize on threads. use anti seize on threads. use anti seize on threads. use anti seize on threads.
4. S 4. S 4. S 4. Spray lubricant on rear t pray lubricant on rear t pray lubricant on rear t pray lubricant on rear tail pipe ail pipe ail pipe ail pipe
hanger rubber grommet. hanger rubber grommet. hanger rubber grommet. hanger rubber grommet.
10. Using care not to damage gasket on 10. Using care not to damage gasket on 10. Using care not to damage gasket on 10. Using care not to damage gasket on
flange, remove the muf
flange, remove the muf flange, remove the muf flange, remove the muffler assembly fler assembly fler assembly fler assembly
pulling out towards the rear of the vehicle. pulling out towards the rear of the vehicle. pulling out towards the rear of the vehicle. pulling out towards the rear of the vehicle.
....
9. Remove the three nut 9. Remove the three nut 9. Remove the three nut 9. Remove the three nuts on the three s on the three s on the three s on the three
bolt flange using a 15mm socket. bolt flange using a 15mm socket. bolt flange using a 15mm socket. bolt flange using a 15mm socket. Y Y Y You ou ou ou
may want to use some penetrating oil. may want to use some penetrating oil. may want to use some penetrating oil. may want to use some penetrating oil.
15. Inst 15. Inst 15. Inst 15. Install rear muf all rear muf all rear muf all rear muffler clamp/hanger (F) fler clamp/hanger (F) fler clamp/hanger (F) fler clamp/hanger (F)
into both rubber grommet into both rubber grommet into both rubber grommet into both rubber grommets, noting that s, noting that s, noting that s, noting that
hanger rod with 2 bends goes towards the hanger rod with 2 bends goes towards the hanger rod with 2 bends goes towards the hanger rod with 2 bends goes towards the
driver
driver driver driveríííís side of vehicle. Slip clamp/hanger s side of vehicle. Slip clamp/hanger s side of vehicle. Slip clamp/hanger s side of vehicle. Slip clamp/hanger
(F) over muf (F) over muf (F) over muf (F) over muffler (B) slip fit joint. Do not fler (B) slip fit joint. Do not fler (B) slip fit joint. Do not fler (B) slip fit joint. Do not
tighten at this time. tighten at this time. tighten at this time. tighten at this time.
20. Check turn out (D) position and 20. Check turn out (D) position and 20. Check turn out (D) position and 20. Check turn out (D) position and
tighten clamp (G) completely
tighten clamp (G) completely tighten clamp (G) completely tighten clamp (G) completely....
21. 21. 21. 21. Af Af Af After inst ter inst ter inst ter installation, it is recommended allation, it is recommended allation, it is recommended allation, it is recommended
that all clamp that all clamp that all clamp that all clamps be retightened and joint s be retightened and joint s be retightened and joint s be retightened and joints s s s
ttttack welded in three spot ack welded in three spot ack welded in three spot ack welded in three spots. s. s. s.
22. Using a sof 22. Using a sof 22. Using a sof 22. Using a soft cloth, remove all print t cloth, remove all print t cloth, remove all print t cloth, remove all prints s s s
from turnout tip (D). from turnout tip (D). from turnout tip (D). from turnout tip (D).
23. Lower vehicle and reatt 23. Lower vehicle and reatt 23. Lower vehicle and reatt 23. Lower vehicle and reattach the negative ach the negative ach the negative ach the negat
battery cable. battery cable. battery cable. battery cable.
NOTES: NOTES: NOTES: NOTES:
1) It may be necessary to loosen and 1) It may be necessary to loosen and 1) It may be necessary to loosen and 1) It may be necessary to loosen and
realign the sp
realign the sp realign the sp realign the spare tire for proper clear- are tire for proper clear- are tire for proper clear- are tire for proper clear­
ive
5. Using a p 5. Using a p 5. Using a p 5. Using a pair of channel lock pliers, air of channel lock pliers, air of channel lock pliers, air of channel lock pliers,
remove hanger rod from bottom hole of remove hanger rod from bottom hole of remove hanger rod from bottom hole of remove hanger rod from bottom hole of
grommet.
grommet. grommet. grommet.
1 1 1 11. Inst 1. Inst 1. Inst 1. Install head pipe all head pipe all head pipe all head pipe (A) with three bolt (A) with three bolt (A) with three bolt (A) with three bolt
flange and tighten with 15mm socket. flange and tighten with 15mm socket. flange and tighten with 15mm socket. flange and tighten with 15mm socket.
NOTE: NOTE: NOTE: NOTE: we recommend using anti seize we recommend using anti seize we recommend using anti seize we recommend using anti seize
on threads. on threads. on threads. on threads.
16. Inst 16. Inst 16. Inst 16. Install short end of t all short end of t all short end of t all short end of tail pipe (C) from ail pipe (C) from ail pipe (C) from ail pipe (C) from
rear into slip joint on muf rear into slip joint on muf rear into slip joint on muf rear into slip joint on muffler (B). fler (B). fler (B). fler (B). T T T Tail pipe ail pipe ail pipe ail pipe
should slip into muf should slip into muf should slip into muf should slip into muffler approx. 2". fler approx. 2". fler approx. 2". fler approx. 2".
NOTE: NOTE: NOTE: NOTE: you may have to t you may have to t you may have to t you may have to tap t ap t ap t ap tail pipe into ail pipe into ail pipe into ail pipe into
ance. ance. ance. ance.
2) 2) 2) 2) All exhaust systems will exp All exhaust systems will exp All exhaust systems will exp All exhaust systems will expand about and about and about and about
1î rearward when exhaust temperature 1î rearward when exhaust temperature 1î rearward when exhaust temperature 1î rearward when exhaust temperature
st
st st start to rise. art to rise. art to rise. art to rise.
3) Use 3) Use 3) Use 3) Use Anti-seize on threads of clamp Anti-seize on threads of clamp Anti-seize on threads of clamp Anti-seize on threads of clamps. s. s. s.
6. Remove t 6. Remove t 6. Remove t 6. Remove tail pipe assembly from rear ail pipe assembly from rear ail pipe assembly from rear ail pipe assembly from rear
of vehicle. of vehicle. of vehicle. of vehicle.
12. Inst 12. Inst 12. Inst 12. Install clamp/hanger (E) into rubber all clamp/hanger (E) into rubber all clamp/hanger (E) into rubber all clamp/hanger (E) into rubber
grommet and slide clamp over head grommet and slide clamp over head grommet and slide clamp over head grommet and slide clamp over head
pipe (A).
pipe (A). pipe (A). pipe (A).
17. Inst 17. Inst 17. Inst 17. Install turn out hanger into bottom all turn out hanger into bottom all turn out hanger into bottom all turn out hanger into bottom
hole of rubber grommet. hole of rubber grommet. hole of rubber grommet. hole of rubber grommet.
muf muf muf muffler with a rubber mallet. fler with a rubber mallet. fler with a rubber mallet. fler with a rubber mallet.
7. S 7. S 7. S 7. Spray lubricant on front and rear pray lubricant on front and rear pray lubricant on front and rear pray lubricant on front and rear
muf muf muf muffler hanger grommet fler hanger grommet fler hanger grommet fler hanger grommets. s. s. s.
13. With the JBA logo to the rear of 13. With the JBA logo to the rear of 13. With the JBA logo to the rear of 13. With the JBA logo to the rear of
vehicle, slip muf
vehicle, slip muf vehicle, slip muf vehicle, slip muffler (B) on head pipe fler (B) on head pipe fler (B) on head pipe fler (B) on head pipe
approximately 2". approximately 2". approximately 2". approximately 2". NOTE: NOTE: NOTE: NOTE: you may have you may have you may have you may have
to t to t to t to tap it in with a rubber mallet. ap it in with a rubber mallet. ap it in with a rubber mallet. ap it in with a rubber mallet.
18. Inst 18. Inst 18. Inst 18. Install 3" clamp (G) over rear of t all 3" clamp (G) over rear of t all 3" clamp (G) over rear of t all 3" clamp (G) over rear of tail ail ail ail
pipe (C). Slip turnout (D) over t pipe (C). Slip turnout (D) over t pipe (C). Slip turnout (D) over t pipe (C). Slip turnout (D) over tail pipe. ail pipe. ail pipe. ail pipe.
Position 3" clamp (G) over slip joint turn Position 3" clamp (G) over slip joint turn Position 3" clamp (G) over slip joint turn Position 3" clamp (G) over slip joint turn
out (D) and hand tighten.
out (D) and hand tighten. out (D) and hand tighten. out (D) and hand tighten. NOTE: NOTE: NOTE: NOTE: use anti use anti use anti use anti
seize on threads. seize on threads. seize on threads. seize on threads.
17099 17099 17099 17099
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.
6-21-02 6-21-02 6-21-02 6-21-02