PerTronix JBA Exhaust 40-9010 - Manual

INSTALLATION INSTRUCTIONS
40-9010
Toyota 4Runner
96-98 2.7L, 3.4L
2/4 WD
TOOLS RECOMMENDED:
TO START:
3/8" drive ratchet
9/16" deep wall socket
1/2" deep wall socket
12mm deep wall socket
14mm deep wall socket
pair of channel lock pliers
reciprocating saw or hack saw
rubber mallet
spray lubricant or penetrating oil
anti-seize
2. Disconnect negative battery cable and
allow vehicle exhaust to cool.
3. With vehicle raised and properly sup-
ported, using a 14mm socket remove two
flange bolts on tail pipe at rear of muffler.
4. Spray lubricant on rear tail pipe hanger
rod, and remove from rubber grommet
using channel lock pliers.
1. Remove and inventory new JBA
exhaust.
5. Remove tail pipe from rear of vehicle.
12. Install oxygen sensor & gasket on
JBA head pipe (A) using two 8mm
nut's (D) and tighten using 1/2'' socket.
NOTE: USE ANTI SEIZE ON THREADS.
13. Install rear muffler clamp/hanger (F)
with ends of hanger rods forward.
14. Install muffler (B) with off set end
toward rear and inward. Slip on 2''.
20. Tighten rear muffler clamp/hanger
(F) completely using a 9/16'' socket.
NOTE: USE ANTI SEIZE ON
THREADS. See Notes #1
20. Check exhaust for proper clear-
ance and location of tip. Retighten all
clamps and tack weld all slip joints in
three spots.
NOTES:
1) If anti seize is not used on threads of
clamps before tightening, the nuts will
gall and clamp will break.
9. Remove muffler assembly, taking care
not to damage flange gasket , it will be
reused.
10. Remove gasket from stock head pipe
flange, and install it on th JBA head pipe.
11. Install JBA head pipe (A) using stock
bolts and tighten using 14mm socket.
8. Spray lubricant on rear muffler hanger
rods and remove from lower holes using
channel lock pliers.
6. Remove oxygen sensor using a 12mm
socket,taking care not to damage gasket
as it will be reused.
7. With muffler properly supported,
remove two flange bolts at front of
muffler using a 14mm socket. Save
bolts they will be reused.
15. Position rear clamp/hanger (F) over
end of muffler and hand tighten only at
this time. NOTE: USE ANTI SEIZE ON
THREADS. See notes #1
16. Install front muffler clamp (E) and
position over slip joint. Align muffler and
tighten clamp (E) completely using a 9/16''
socket. NOTE: USE ANTI SEIZE ON
THREADS. See Notes #1
17. Install tail pipe (C) from rear of vehicle
and slip into rear of muffler 2''.
18. Install rear tail pipe hanger rod into
lower hole in rubber grommet.
19. Rotate tail pipe (C) for proper clear-
ance on rear body panel and rear cross
member. Clearance on cross member
should be 1'' to 1-1/2''.
We recommend taking the truck to a muffler shop and having all slip connections tack welded.
Parts List
A. Head pipe with hanger 1
B. Muffler 1
C. Tail pipe with tip 1
D. 8mm nuts 2
G. Block off plate (not shown) 1
H. Gasket (not shown) 1
E. 2-1/2" clamp 1
F. 2-1/2" rear muffler clamp/hanger 1
**Installation recommendation:
JBA recommends in most cases that the vehicle be taken to a reputable exhaust shop.
E
F
A
C
B D
2.7.06
21. Lower vehicle and reattach negative
battery cable.