PerTronix JBA Exhaust 40-3003 - Manual

INSTALLATION INSTRUCTIONS
GM Pickup
96-98 V8-5.7L Std. cab, Std. bed
T OOLS RECOMMENDED:
T O ST ART :
reciprocating saw or hack saw
prybar
rubber mallet
ratchet
15mm deep socket
9/16 box wrench or socket
7/8" open end wrench
pair of channel lock pliers
13mm socket
anti-seize
impact wrench
spray lubricant or penetrating oil
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 3"
behind rear muffler hanger.
4. Spray lubricant on rear tail pipe hanger
grommet.
INSTALLATION INSTRUCTIONS
GM Pickup
96-98 V8-5.7L Std. cab, Std. bed
T OOLS RECOMMENDED:
T O ST ART :
reciprocating saw or hack saw
prybar
rubber mallet
ratchet
15mm deep socket
9/16 box wrench or socket
7/8" open end wrench
pair of channel lock pliers
13mm socket
anti-seize
impact wrench
spray lubricant or penetrating oil
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 3"
behind rear muffler hanger.
4. Spray lubricant on rear tail pipe hanger
grommet.
INSTALLATION INSTRUCTIONS
GM Pickup
96-98 V8-5.7L Std. cab, Std. bed
T OOLS RECOMMENDED:
T O ST ART :
reciprocating saw or hack saw
prybar
rubber mallet
ratchet
15mm deep socket
9/16 box wrench or socket
7/8" open end wrench
pair of channel lock pliers
13mm socket
anti-seize
impact wrench
spray lubricant or penetrating oil
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 3"
behind rear muffler hanger.
4. Spray lubricant on rear tail pipe hanger
grommet.
INSTALLATION INSTRUCTIONS
GM Pickup
96-98 V8-5.7L Std. cab, Std. bed
T OOLS RECOMMENDED:
T O ST ART :
reciprocating saw or hack saw
prybar
rubber mallet
ratchet
15mm deep socket
9/16 box wrench or socket
7/8" open end wrench
pair of channel lock pliers
13mm socket
anti-seize
impact wrench
spray lubricant or penetrating oil
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 3"
behind rear muffler hanger.
4. Spray lubricant on rear tail pipe hanger
grommet.
5. Using a pair of channel lock pliers,
remove hanger rod from bottom hole of
grommet.
9. Remove three nuts on three bolt flange
using 15mm socket. You may want to use
some penetrating oil.
1. Remove and inventory new JBA
exhaust.
10. Using a pair of channel lock pliers,
remove front and rear muffler hanger rods
from bottom holes of grommets.
Note: support muffler before starting.
6. Remove tail pipe assembly from the
rear of vehicle.
11. Remove muffler assembly pulling
towards rear of vehicle. Note: use care not
to damage gasket on three bolt flange.
15. With muffler (B) in place, install muf-
fler clamp (E) on slip fit joint. Position 1/4"
from lip. Tighten clamp completely with
9/16" deep wall socket. NOTE: Use some
anti-seize on all threads.
16. Install rear muffler clamp/hanger (F)
over slip joint on rear of muffler. Do not
tighten at this time.
17. Slip clamp/hanger (F) into lower hole
on rubber grommet.
24. Using a soft cloth, remove all prints
from turnout tip.
25. Lower vehicle and reattach the nega-
tive battery cable.
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 D,
E and F.
12. Install head pipe (A) with three bolt
flange. Install hanger through lower hole
in rubber grommet. Tighten three nuts
using 15mm socket.
Note: we recom-
mend using anti-seize on threads.
13. Install oxygen sensor using 7/8"
wrench.
14. Slip muffler (B) on head pipe approxi-
mately 2". Note: You may have to tap it in
with a rubber mallet. Make sure JBA logo
is to the rear.
8. Remove oxygen sensor with 7/8" open
end wrench.
5. Using a pair of channel lock pliers,
remove hanger rod from bottom hole of
grommet.
9. Remove three nuts on three bolt flange
using 15mm socket. You may want to use
some penetrating oil.
1. Remove and inventory new JBA
exhaust.
10. Using a pair of channel lock pliers,
remove front and rear muffler hanger rods
from bottom holes of grommets.
Note: support muffler before starting.
6. Remove tail pipe assembly from the
rear of vehicle.
11. Remove muffler assembly pulling
towards rear of vehicle. Note: use care not
to damage gasket on three bolt flange.
15. With muffler (B) in place, install muf-
fler clamp (E) on slip fit joint. Position 1/4"
from lip. Tighten clamp completely with
9/16" deep wall socket. NOTE: Use some
anti-seize on all threads.
16. Install rear muffler clamp/hanger (F)
over slip joint on rear of muffler. Do not
tighten at this time.
17. Slip clamp/hanger (F) into lower hole
on rubber grommet.
24. Using a soft cloth, remove all prints
from turnout tip.
25. Lower vehicle and reattach the nega-
tive battery cable.
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 D,
E and F.
12. Install head pipe (A) with three bolt
flange. Install hanger through lower hole
in rubber grommet. Tighten three nuts
using 15mm socket.
Note: we recom-
mend using anti-seize on threads.
13. Install oxygen sensor using 7/8"
wrench.
14. Slip muffler (B) on head pipe approxi-
mately 2". Note: You may have to tap it in
with a rubber mallet. Make sure JBA logo
is to the rear.
8. Remove oxygen sensor with 7/8" open
end wrench.
5. Using a pair of channel lock pliers,
remove hanger rod from bottom hole of
grommet.
9. Remove three nuts on three bolt flange
using 15mm socket. You may want to use
some penetrating oil.
1. Remove and inventory new JBA
exhaust.
10. Using a pair of channel lock pliers,
remove front and rear muffler hanger rods
from bottom holes of grommets.
Note: support muffler before starting.
6. Remove tail pipe assembly from the
rear of vehicle.
11. Remove muffler assembly pulling
towards rear of vehicle. Note: use care not
to damage gasket on three bolt flange.
15. With muffler (B) in place, install muf-
fler clamp (E) on slip fit joint. Position 1/4"
from lip. Tighten clamp completely with
9/16" deep wall socket. NOTE: Use some
anti-seize on all threads.
16. Install rear muffler clamp/hanger (F)
over slip joint on rear of muffler. Do not
tighten at this time.
17. Slip clamp/hanger (F) into lower hole
on rubber grommet.
24. Using a soft cloth, remove all prints
from turnout tip.
25. Lower vehicle and reattach the nega-
tive battery cable.
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 D,
E and F.
12. Install head pipe (A) with three bolt
flange. Install hanger through lower hole
in rubber grommet. Tighten three nuts
using 15mm socket.
Note: we recom-
mend using anti-seize on threads.
13. Install oxygen sensor using 7/8"
wrench.
14. Slip muffler (B) on head pipe approxi-
mately 2". Note: You may have to tap it in
with a rubber mallet. Make sure JBA logo
is to the rear.
8. Remove oxygen sensor with 7/8" open
end wrench.
5. Using a pair of channel lock pliers,
remove hanger rod from bottom hole of
grommet.
9. Remove three nuts on three bolt flange
using 15mm socket. You may want to use
some penetrating oil.
1. Remove and inventory new JBA
exhaust.
10. Using a pair of channel lock pliers,
remove front and rear muffler hanger rods
from bottom holes of grommets.
Note: support muffler before starting.
6. Remove tail pipe assembly from the
rear of vehicle.
11. Remove muffler assembly pulling
towards rear of vehicle. Note: use care not
to damage gasket on three bolt flange.
15. With muffler (B) in place, install muf-
fler clamp (E) on slip fit joint. Position 1/4"
from lip. Tighten clamp completely with
9/16" deep wall socket. NOTE: Use some
anti-seize on all threads.
16. Install rear muffler clamp/hanger (F)
over slip joint on rear of muffler. Do not
tighten at this time.
17. Slip clamp/hanger (F) into lower hole
on rubber grommet.
24. Using a soft cloth, remove all prints
from turnout tip.
25. Lower vehicle and reattach the nega-
tive battery cable.
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 D,
E and F.
12. Install head pipe (A) with three bolt
flange. Install hanger through lower hole
in rubber grommet. Tighten three nuts
using 15mm socket.
Note: we recom-
mend using anti-seize on threads.
13. Install oxygen sensor using 7/8"
wrench.
14. Slip muffler (B) on head pipe approxi-
mately 2". Note: You may have to tap it in
with a rubber mallet. Make sure JBA logo
is to the rear.
8. Remove oxygen sensor with 7/8" open
end wrench.
7. Spray lubricant on front and rear muffler
hanger grommets. 7. Spray lubricant on front and rear muffler
hanger grommets. 7. Spray lubricant on front and rear muffler
hanger grommets. 7. Spray lubricant on front and rear muffler
hanger grommets.
18. Install tail pipe (C) from rear into slip
joint on muffler (B). Slip approx. 2". 18. Install tail pipe (C) from rear into slip
joint on muffler (B). Slip approx. 2". 18. Install tail pipe (C) from rear into slip
joint on muffler (B). Slip approx. 2". 18. Install tail pipe (C) from rear into slip
joint on muffler (B). Slip approx. 2".
19. Slip rear tail pipe (C) hanger into
lower hole in rubber grommet. 19. Slip rear tail pipe (C) hanger into
lower hole in rubber grommet. 19. Slip rear tail pipe (C) hanger into
lower hole in rubber grommet. 19. Slip rear tail pipe (C) hanger into
lower hole in rubber grommet.
20. Position tail pipe (C) so hanger is not
cocked at an angle, and rubber grommet
is angled forward.
21. Inspect clearance around rear-end
shock and spare tire.
22. Position rear muffler clamp/hanger (F)
1/4" from lip on slip joint and tighten com-
pletely with 9/16" deep wall socket. Note:
Use anti-seize on threads.
23. Slip turn out clamp (G) onto tail pipe.
Slip turn out (D) on tail pipe (C) approx.
1-1/2î. Rotate tip to desired position leav-
ing clearance from body. Position clamp
(G) with threads in an upward position.
Tighten completely with 9/16" deep wall
socket. Note: use anti-seize on threads.
20. Position tail pipe (C) so hanger is not
cocked at an angle, and rubber grommet
is angled forward.
21. Inspect clearance around rear-end
shock and spare tire.
22. Position rear muffler clamp/hanger (F)
1/4" from lip on slip joint and tighten com-
pletely with 9/16" deep wall socket. Note:
Use anti-seize on threads.
23. Slip turn out clamp (G) onto tail pipe.
Slip turn out (D) on tail pipe (C) approx.
1-1/2î. Rotate tip to desired position leav-
ing clearance from body. Position clamp
(G) with threads in an upward position.
Tighten completely with 9/16" deep wall
socket. Note: use anti-seize on threads.
20. Position tail pipe (C) so hanger is not
cocked at an angle, and rubber grommet
is angled forward.
21. Inspect clearance around rear-end
shock and spare tire.
22. Position rear muffler clamp/hanger (F)
1/4" from lip on slip joint and tighten com-
pletely with 9/16" deep wall socket. Note:
Use anti-seize on threads.
23. Slip turn out clamp (G) onto tail pipe.
Slip turn out (D) on tail pipe (C) approx.
1-1/2î. Rotate tip to desired position leav-
ing clearance from body. Position clamp
(G) with threads in an upward position.
Tighten completely with 9/16" deep wall
socket. Note: use anti-seize on threads.
20. Position tail pipe (C) so hanger is not
cocked at an angle, and rubber grommet
is angled forward.
21. Inspect clearance around rear-end
shock and spare tire.
22. Position rear muffler clamp/hanger (F)
1/4" from lip on slip joint and tighten com-
pletely with 9/16" deep wall socket. Note:
Use anti-seize on threads.
23. Slip turn out clamp (G) onto tail pipe.
Slip turn out (D) on tail pipe (C) approx.
1-1/2î. Rotate tip to desired position leav-
ing clearance from body. Position clamp
(G) with threads in an upward position.
Tighten completely with 9/16" deep wall
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 with hanger 1
B. Muffler 24" 1
C. Tail pipe with hanger 1
D. Turn out 1
E. Front muffler clamp 3" 1
F. Rear muffler clamp/hanger 3" 1
G. Turn out clamp 3" 1
**Inst allation recommendation:
JBA recommends in most cases that the vehicle be taken to a reputable exhaust shop.
17092
We recommend taking the truck to a muffler shop and having all slip connections tack welded.
Part s List
A. Head pipe with hanger 1
B. Muffler 24" 1
C. Tail pipe with hanger 1
D. Turn out 1
E. Front muffler clamp 3" 1
F. Rear muffler clamp/hanger 3" 1
G. Turn out clamp 3" 1
**Inst allation recommendation:
JBA recommends in most cases that the vehicle be taken to a reputable exhaust shop.
17092
We recommend taking the truck to a muffler shop and having all slip connections tack welded.
Part s List
A. Head pipe with hanger 1
B. Muffler 24" 1
C. Tail pipe with hanger 1
D. Turn out 1
E. Front muffler clamp 3" 1
F. Rear muffler clamp/hanger 3" 1
G. Turn out clamp 3" 1
**Inst allation recommendation:
JBA recommends in most cases that the vehicle be taken to a reputable exhaust shop.
17092
We recommend taking the truck to a muffler shop and having all slip connections tack welded.
Part s List
A. Head pipe with hanger 1
B. Muffler 24" 1
C. Tail pipe with hanger 1
D. Turn out 1
E. Front muffler clamp 3" 1
F. Rear muffler clamp/hanger 3" 1
G. Turn out clamp 3" 1
**Inst allation recommendation:
JBA recommends in most cases that the vehicle be taken to a reputable exhaust shop.
17092
D
C
B
G
F E
A
D
C
B
G
F E
A
D
C
B
G
F E
A
D
C
B
G
F E
A
40-3003
4/17/07