JBA 40-1520 User Manual
Installation instructions, Inst, Part

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.
Part
Part
Part
Part s List
s List
s List
s List
40-1520
A.
A.
A.
A. Head pipe
Head pipe
Head pipe
Head pipe
1
1
1
1
2002 Dodge Ram quad cab/std. bed 4.7/5.9L V-8
B.
B.
B.
B. Muf
Muf
Muf
Muffler
fler
fler
fler, 24"
1
1
1
1
C.
C.
C.
C. T
T
T
Tail pipe
ail pipe
ail pipe
ail pipe
1
1
1
1
40-1521
D.
D.
D.
D. T
T
T
Turn out
urn out
urn out
urn out
1
1
1
1
E.
E.
E.
E.
G
G
G
G
2-1/2" clamp
1
1
1
1
2002 Dodge Ram std. cab/short bed 4.7/5.9L V-8
F. 3" clamp hanger
G. 3" clamp hanger
H. 3" clamp
F.
G.
H.
F.
G.
H.
F.
G.
H.
H
D
E
A
A
A
B
F
E
E
E
A (For 1520)
C
1
1
1
1
T
T
T
T OOLS RECOMMENDED:
OOLS RECOMMENDED:
OOLS RECOMMENDED:
OOLS RECOMMENDED:
1
1
1
1
1
1
1
1
9/16 deep socket
9/16 deep socket
9/16 deep socket
9/16 deep socket
ratchet
ratchet
ratchet
ratchet
10mm wrench
10mm wrench
10mm wrench
10mm wrench
15mm deep socket
15mm deep socket
15mm deep socket
15mm deep socket
prybar
prybar
prybar
prybar
rubber mallet
rubber mallet
rubber mallet
rubber mallet
spray lubricant or penetrating oil
spray lubricant or penetrating oil
spray lubricant or penetrating oil
spray lubricant or penetrating oil
anti-seize
anti-seize
anti-seize
anti-seize
reciprocating saw or hack saw
reciprocating saw or hack saw
reciprocating saw or hack saw
reciprocating saw or hack saw
p
p
p
pair of channel lock pliers
air of channel lock pliers
air of channel lock pliers
air of channel lock pliers
T
T
T
T O
O
O
O ST
ST
ST
ST ART
ART
ART
ART ::::
A (For 1521)
ail pipe approximately 1" behind
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.
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 t
, cut t
, cut t
, cut t
rear muf
rear muf
rear muf
rear muffler clamp and in front of t
fler clamp and in front of t
fler clamp and in front of t
fler clamp and in front of tail pipe
ail pipe
ail pipe
ail pipe
hanger
hanger
hanger
hanger....
4. S
4. S
4. S
4. Spray lubricant on lower holes of front
pray lubricant on lower holes of front
pray lubricant on lower holes of front
pray lubricant on lower holes of front
and rear t
and rear t
and rear t
and rear tail pipe hanger rubber grommet
ail pipe hanger rubber grommet
ail pipe hanger rubber grommet
ail pipe hanger rubber grommets.
s.
s.
s.
1. Remove and inventory new JBA
exhaust.
exhaust.
exhaust.
exhaust.
head pipe (A) using the 2-1/2" clamp (E).
ighten completely with 9/16" deep wall
8. Using some form of heat and force,
8. Using some form of heat and force,
8. Using some form of heat and force,
8. Using some form of heat and force,
disengage and remove muf
disengage and remove muf
disengage and remove muf
disengage and remove muffler without
fler without
fler without
fler without
damaging head pipe.
damaging head pipe.
damaging head pipe.
damaging head pipe.
9.
9.
9.
9. Align notch with locating pin and inst
Align notch with locating pin and inst
Align notch with locating pin and inst
Align notch with locating pin and install
all
all
all
T
T
T
T
socket.
socket.
socket.
socket.
Note:
Note:
Note:
Note:
Use anti-seize on threads.
Use anti-seize on threads.
Use anti-seize on threads.
Use anti-seize on threads.
7. Remove t
7. Remove t
7. Remove t
7. Remove tail pipe from rear of vehicle.
ail pipe from rear of vehicle.
ail pipe from rear of vehicle.
ail pipe from rear of vehicle.
ail pipe and tighten 3"
13. Inst
13. Inst
13. Inst
13. Install front two hangers on t
all front two hangers on t
all front two hangers on t
all front two hangers on tail pipe
ail pipe
ail pipe
ail pipe
(C) into lower holes of rubber grommet.
(C) into lower holes of rubber grommet.
(C) into lower holes of rubber grommet.
(C) into lower holes of rubber grommet.
14. Inst
14. Inst
14. Inst
14. Install rear t
all rear t
all rear t
all rear tail pipe hanger into rubber
ail pipe hanger into rubber
ail pipe hanger into rubber
ail pipe hanger into rubber
grommet.
grommet.
grommet.
grommet. Align t
Align t
Align t
Align t
clamp (G) completely
clamp (G) completely
clamp (G) completely
clamp (G) completely....
Note:
Note:
Note:
Note:
Use anti-
Use anti-
Use anti-
Use anti
seize on threads.
seize on threads.
seize on threads.
seize on threads.
1" rearward when exhaust temperature
20.
20.
20.
20. 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 3 spot
ack welded in 3 spot
ack welded in 3 spot
ack welded in 3 spots.
s.
s.
s.
21. Using a sof
21. Using a sof
21. Using a sof
21. 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.
22. Lower vehicle and reatt
22. Lower vehicle and reatt
22. Lower vehicle and reatt
22. Lower vehicle and reattach the nega-
ach the nega-
ach the nega-
ach the nega
tive battery cable.
tive battery cable.
tive battery cable.
tive 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
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
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.
ighten clamp (H) completely
using 9/16" deep wall socket.
19.
19.
19.
19. T
T
T
T
Note:
Note:
Note:
Note:
Use anti-seize on threads.
Use anti-seize on threads.
Use anti-seize on threads.
Use anti-seize on threads.
11. Using the 3" clamp (F), tighten clamp
completely using 9/16" deep wall socket.
10. With JBA logo facing rear of vehicle,
10. With JBA logo facing rear of vehicle,
10. With JBA logo facing rear of vehicle,
10. With JBA logo facing rear of vehicle,
inst
inst
inst
install muf
all muf
all muf
all muffler (B) over head pipe (A) mak-
fler (B) over head pipe (A) mak-
fler (B) over head pipe (A) mak-
fler (B) over head pipe (A) mak
ing sure muf
ing sure muf
ing sure muf
ing sure muffler bottoms out on slip joint.
fler bottoms out on slip joint.
fler bottoms out on slip joint.
fler bottoms out on slip joint.
all turn out clamp (H)
15. Inst
15. Inst
15. Inst
15. Inst
over end of t
over end of t
over end of t
over end of tail pipe (C) and into rubber
ail pipe (C) and into rubber
ail pipe (C) and into rubber
ail pipe (C) and into rubber
grommet.
grommet.
grommet.
grommet.
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
two rear t
two rear t
two rear t
two rear tail pipe rubber grommet
ail pipe rubber grommet
ail pipe rubber grommet
ail pipe rubber grommets.
s.
s.
s.
6. Using a p
6. Using a p
6. Using a p
6. Using a pair of channel lock pliers,
air of channel lock pliers,
air of channel lock pliers,
air of channel lock pliers,
remove front t
remove front t
remove front t
remove front tail pipe hanger rod from
ail pipe hanger rod from
ail pipe hanger rod from
ail pipe hanger rod from
bottom hole in rubber grommet.
bottom hole in rubber grommet.
bottom hole in rubber grommet.
bottom hole in rubber grommet.
12. Inst
12. Inst
12. Inst
12. Install t
all t
all t
all tail pipe (C) from rear of vehi-
ail pipe (C) from rear of vehi-
ail pipe (C) from rear of vehi-
ail pipe (C) from rear of vehi
cle with double hanger towards muf
cle with double hanger towards muf
cle with double hanger towards muf
cle with double hanger towards muffler
fler
fler
fler....
ate to desired position approx. 1"
18. Inst
18. Inst
18. Inst
18. Install turn out (D) to end of t
all turn out (D) to end of t
all turn out (D) to end of t
all turn out (D) to end of tail pipe
ail pipe
ail pipe
ail pipe
(C) rot
(C) rot
(C) rot
(C) rot
from body
from body
from body
from body....
17039a
17039a
17039a
17039a
W
W
We
e
e recommend t
recommend t
recommend t aking the truck to a muffler shop and having all slip connections tack welded.
We
7-3-02