PerTronix JBA Exhaust 40-3028 - Manual

INSTALLATION INSTRUCTIONS
**Installation recommendation:
JBA recommends in most cases that the vehicle be taken to a reputable exhaust shop.
40-3028
96-00 Chevrolet Tahoe / GMC Yukon
4 Door, V-8 5.7L 2/4 wd
T T T T OOLS RECOMMENDED: Parts List
ratchet A. Head pipe 1
9/16" deep socket B. Muffler 24" 1
15mm deep socket C. Tail pipe with 1
pair of channel lock pliers D. Turn out with hanger 1 F B
F
reciprocating saw or hack saw E. Front muffler clamp/hanger 3" 1
A
C
rubber mallet F... 3" clamp 2 D E
spray lubricant or penetrating oil
anti-seize
prybar
T T T T O O O O ST ST ST START ART ART ART::::
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 Evolª 1. Remove and inventory new Evolª 1. Remove and inventory new Evolª 1. Remove and inventory new Evolª
exhaust.
exhaust. exhaust. exhaust.
8. S 8. S 8. S 8. Spray lubricant on front muf pray lubricant on front muf pray lubricant on front muf pray lubricant on front muffler hanger fler hanger fler hanger fler hanger
grommet. grommet. grommet. grommet.
14. With the JBA logo to the rear of the
vehicle, slip muf
vehicle, slip muf vehicle, slip muf vehicle, slip muffler (B) on head pipe (A). fler (B) on head pipe (A). fler (B) on head pipe (A). fler (B) on head pipe (A).
NO NO NO NOTE: TE: TE: TE: Y Y Y You may have to t ou may have to t ou may have to t ou may have to tap it with a ap it with a ap it with a ap it with a
rubber mallet. rubber mallet. rubber mallet. rubber mallet.
20. Install turnout (D) slip joint over end all turnout (D) slip joint over end all turnout (D) slip joint over end all turnout (D) slip joint over end
of t of t of t of tail pipe (C). ail pipe (C). ail pipe (C). ail pipe (C).
3. With vehicle raised and properly sup- 3. With vehicle raised and properly sup- 3. With vehicle raised and properly sup- 3. With vehicle raised and properly sup­
ported, using a reciprocating saw or hack
ported, using a reciprocating saw or hack ported, using a reciprocating saw or hack ported, using a reciprocating saw or hack
saw
saw saw saw, cut the t , cut the t , cut the t , cut the tail pipe approximately 1" ail pipe approximately 1" ail pipe approximately 1" ail pipe approximately 1"
behind rear muf behind rear muf behind rear muf behind rear muffler hanger fler hanger fler hanger fler hanger....
9. With muf 9. With muf 9. With muf 9. With muffler and head pipe properly fler and head pipe properly fler and head pipe properly fler and head pipe properly
supported, using a p supported, using a p supported, using a p supported, using a pair of channel lock air of channel lock air of channel lock air of channel lock
pliers, remove hanger rod from bottom pliers, remove hanger rod from bottom pliers, remove hanger rod from bottom pliers, remove hanger rod from bottom
hole of grommet.
hole of grommet. hole of grommet. hole of grommet.
15. Position 3" clamp (F) on muffler (B) fler (B) fler (B) fler (B)
and using a 9/16" deep socket, tighten and using a 9/16" deep socket, tighten and using a 9/16" deep socket, tighten and using a 9/16" deep socket, tighten
completely
completely completely completely.... NO NO NO NOTE: TE: TE: TE: use anti-seize on threads. use anti-seize on threads. use anti-seize on threads. use anti-seize on threads.
n.
4. S 4. S 4. S 4. Spray lubricant on front and rear t pray lubricant on front and rear t pray lubricant on front and rear t pray lubricant on front and rear tail ail ail ail
pipe rubber grommet. pipe rubber grommet. pipe rubber grommet. pipe rubber grommet.
10. Remove muf 10. Remove muf 10. Remove muf 10. Remove muffler and head pipe fler and head pipe fler and head pipe fler and head pipe
assembly assembly assembly assembly....
16. Install t all t all t all tail pipe (C) into rear slip joint ail pipe (C) into rear slip joint ail pipe (C) into rear slip joint ail pipe (C) into rear slip joint
on muf on muf on muf on muffler (B). fler (B). fler (B). fler (B). NO NO NO NOTE: TE: TE: TE: ttttail pipe (C) ail pipe (C) ail pipe (C) ail pipe (C)
should be inst should be inst should be inst should be installed with the hanger to alled with the hanger to alled with the hanger to alled with the hanger to
the rear of the vehicle. the rear of the vehicle. the rear of the vehicle. the rear of the vehicle.
24. 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. from turnout tip. from turnout tip. from turnout tip.
21. Position turnout (D) to desired positio
23.
22. Position 3" clamp (I) over turnout (D)
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
be t be t be t be tack welded in three spot. ack welded in three spot. ack welded in three spot. ack welded in three spot.
slip joint and tighten completely using a slip joint and tighten completely using a slip joint and tighten completely using a slip joint and tighten completely using a
9/16" deep socket.
9/16" deep socket. 9/16" deep socket. 9/16" deep socket. NO NO NO NOTE: TE: TE: TE: use anti-seize use anti-seize use anti-seize use anti-seize
on threads. on threads. on threads. on threads.
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 rods from bottom holes of remove hanger rods from bottom holes of remove hanger rods from bottom holes of remove hanger rods from bottom holes of
front and rear t
front and rear t front and rear t front and rear tailpipe rubber grommet ailpipe rubber grommet ailpipe rubber grommet ailpipe rubber grommets. s. s. s.
6. Remove t 6. Remove t 6. Remove t 6. Remove tail pipe assembly from the ail pipe assembly from the ail pipe assembly from the ail pipe assembly from the
rear of vehicle. rear of vehicle. rear of vehicle. rear of vehicle.
all head pipe (G) hanger into
all
1 1 1 11. Inst 1. Inst 1. Inst 1. Inst
bottom hole of rubber grommet. bottom hole of rubber grommet. bottom hole of rubber grommet. bottom hole of rubber grommet.
12. Inst 12. Inst 12. Inst 12. Install head pipe over studs and inst all head pipe over studs and inst all head pipe over studs and inst all head pipe over studs and inst
flange nut flange nut flange nut flange nuts and align flange. using a s and align flange. using a s and align flange. using a s and align flange. using a
15mm socket and ratchet, tighten nut 15mm socket and ratchet, tighten nut 15mm socket and ratchet, tighten nut 15mm socket and ratchet, tighten nuts s s s
completely completely completely completely.... NO NO NO NOTE: TE: TE: TE: we recommend using we recommend using we recommend using we recommend using
anti-seize on threads. anti-seize on threads. anti-seize on threads. anti-seize on threads.
17. Install t all t all t all tail pipe (C) hanger rod into ail pipe (C) hanger rod into ail pipe (C) hanger rod into ail pipe (C) hanger rod into
bottom hole of rear rubber hanger bottom hole of rear rubber hanger bottom hole of rear rubber hanger bottom hole of rear rubber hanger
grommet.
grommet. grommet. grommet.
18. With tail pipe (C) aligned to desired ail pipe (C) aligned to desired ail pipe (C) aligned to desired ail pipe (C) aligned to desired
position, using a 9/16" deep socket, position, using a 9/16" deep socket, position, using a 9/16" deep socket, position, using a 9/16" deep socket,
tighten nut
tighten nut tighten nut tighten nuts on rear muf s on rear muf s on rear muf s on rear muffler hanger (F) fler hanger (F) fler hanger (F) fler hanger (F)
completely completely completely completely....
NO NO NO NOTE: TE: TE: TE: use anti-seize on threads. use anti-seize on threads. use anti-seize on threads. use anti-seize on threads.
25. Lower vehicle and reatt
26. Run vehicle until exhaust reaches
ach the ach the ach the ach the
negative battery cable. negative battery cable. negative battery cable. negative battery cable.
operating temperature and retighten the operating temperature and retighten the operating temperature and retighten the operating temperature and retighten the
two 15mm flange nut
two 15mm flange nut two 15mm flange nut two 15mm flange nuts. s. s. s.
NO NO NO NOTES: TES: TES: TES:
1) 1) 1) 1) 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
1" rearward when exhaust temperature 1" rearward when exhaust temperature 1" rearward when exhaust temperature 1" rearward when exhaust temperature
st
st st start to rise. art to rise. art to rise. art to rise.
2) Use 2) Use 2) Use 2) 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 E, s E, s E, s E
F and G F and G F and G F and G....
,
7. Using a 15mm socket and ratchet, 7. Using a 15mm socket and ratchet, 7. Using a 15mm socket and ratchet, 7. Using a 15mm socket and ratchet,
remove flange nut
remove flange nut remove flange nut remove flange nuts from head pipe. s from head pipe. s from head pipe. s from head pipe.
13. Install 3" clamp with hanger (G) over
head pipe (A).
19. Install 3" clamp (G) over end of t all 3" clamp (G) over end of t all 3" clamp (G) over end of t all 3" clamp (G) over end of tail ail ail ail
pipe (C). pipe (C). pipe (C). pipe (C).
W W W We e e e rrrrec ec ec ecommend tak ommend tak ommend tak ommend taking the truck t ing the truck t ing the truck t ing the truck to a muffler shop and ha o a muffler shop and ha o a muffler shop and ha o a muffler shop and having all slip c ving all slip c ving all slip c ving all slip connec onnec onnec onnections tack w tions tack w tions tack w tions tack welded elded elded elded.... 04/07