PerTronix JBA Exhaust 40-1506 - Manual

INSTALLATION INSTRUCTIONS
40-1506
1993-97 Jeep Grand Cherokee
5.2L V8 2/4 WD
TOOLS RECOMMENDED:
TO START:
3/8" ratchet
9/16 deep socket
15mm deep socket
11/16" socket
3/8" extension
rubber mallet
anti-seize
spray lubricant or penetrating oil
reciprocating saw or hack saw
pair of channel lock pliers 10"
2. Disconnect negative battery cable and
allow vehicle exhaust to cool.
3. With vehicle raised and properly sup-
ported, remove tail pipe heat shield by
gas tank using a 10mm socket.
4. With muffler properly supported, using a
reciprocating saw or hack saw, cut tail pipe
off 5'' behind rear of muffler.
5. Using channel lock pliers, remove tail
pipe hanger rod from lower hole in rubber
grommet.
15. Starting from rear of vehicle, install
tail pipe (C) into rear muffler slip joint.
1. Remove and inventory new JBA
exhaust.
6. Remove tail pipe from rear of vehicle.
7. Remove front muffler clamp at slip
joint, using a 15mm socket.
20. Check exhaust kit for proper clear-
ances, and tack weld all slip joints in
three spots.
21. Using a soft cloth, remove all prints
from turnout tip.
22. Lower vehicle and reattach the
negative battery cable.
NOTES:
1.
If anti seize is not used on threads of
clamps before tightening, the nut's will
gall, and clamp rod will break.
11. With rod pointing toward driver's side,
install rear muffler clamp/hanger (F) into
lower hole of rubber grommet (G).
12.
Install muffler on head pipe making sure
slip joint is bottomed out. NOTE: You may
have to tap on with rubber mallet.
13. Slip clamp/hanger (F) over end of
rear muffler slip joint, and hand tighten
only at this time. NOTE: USE ANTI SEIZE
ON THREADS. See notes #1
8. Using some form of heat and force,
remove muffler assembly without damag-
ing catalytic converter pipe.
9. Slip 2 1/4''clamp (D) over front of head
pipe (A) and install, aligning notch with
pin. NOTE: You may have to tap on with
rubber mallet. Align clamp (D) over slip
joint and tighten completely using a
9/16''deep wall socket. NOTE: USE ANTI
SEIZE ON THREADS. See note #1
10. Install rubber grommet (G) over upper
rear muffler hanger rod (H). With rod
pointing toward drivers side, attach to
7/16''-20 stud on floor pan above rear
muffler location, using 7/16''-20 nut (I).
Tighten completely using a 11/16''socket.
14. Install 2 1/2''clamp (E) over front muf-
fler slip joint. With muffler properly aligned
tighten clamp (E) completely using a
9/16''deep wall socket. NOTE: USE ANTI
SEIZE ON THREADS. See notes #1
16. Install rear tail pipe hanger rod into
lower hole in rubber grommet.
17. Reinstall the tail pipe heat shield using
a 10mm socket.
18. Rotate tail pipe (C) to position rear
hanger and chrome tip.
19. Tighten rear muffler clamp/hanger (F)
completely using a 9/16'' deep wall sock-
et. NOTE: USE ANTI SEIZE ON
THREADS. See notes #1
We recommend taking the truck to a muffler shop and having all slip connections tack welded.
Parts List
A. Head pipe 1
B. Muffler, oval 24" 1
C. Tail pipe w/tip 1
D. 2-1/4" clamp 1
E. 2-1/2" clamp 1
F. Rear muffler clamp/hanger 1
G. Rubber grommet 1
H. Upper rear muffler hanger rod 1
I. 7/16"-20 hex nut
1
**Inst allation recommendation:
JBA recommends in most cases that the vehicle be taken to a reputable exhaust shop.
17006
B
A
D
E
C
F
G
H
I