JBA 40-2509 User Manual
Installation instructions, Inst

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.
JBA recommends in most cases that the vehicle be taken to a reputable exhaust shop.
JBA recommends in most cases that the vehicle be taken to a reputable exhaust shop.
JBA recommends in most cases that the vehicle be taken to a reputable exhaust shop.
40-2509
1988-94 Ford F-250, F-350
1988-94 Ford F-250, F-350
1988-94 Ford F-250, F-350
1988-94 Ford F-250, F-350
V8-5.8L, 7.5L
V8-5.8L, 7.5L
V8-5.8L, 7.5L
V8-5.8L, 7.5L Ext. cab/Long bed
Ext. cab/Long bed
Ext. cab/Long bed
Ext. cab/Long bed
T
T
T
T OOLS RECOMMENDED:
OOLS RECOMMENDED:
OOLS RECOMMENDED:
OOLS RECOMMENDED:
ratchet
ratchet
ratchet
ratchet
9/16 deep socket
9/16 deep socket
9/16 deep socket
9/16 deep socket
15mm deep socket
15mm deep socket
15mm deep socket
15mm deep socket
9/16" box wrench
9/16" box wrench
9/16" box wrench
9/16" box wrench
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, 12"
air of channel lock pliers, 12"
air of channel lock pliers, 12"
air of channel lock pliers, 12"
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
Part
Part
Part
Part s List
s List
s List
s List
A.
A.
A.
A. Head pipe
Head pipe
Head pipe
Head pipe
1
1
1
1
E.
E.
E.
E. 2-1/2" H.P
2-1/2" H.P
2-1/2" H.P
2-1/2" H.P. clamp
. clamp
. clamp
. clamp
1
1
1
1
B.
B.
B.
B. Muf
Muf
Muf
Muffler
fler
fler
fler, 24"
, 24"
, 24"
, 24"
1
1
1
1
F
F
F
F.... Front muf
Front muf
Front muf
Front muffler 3" clamp/hanger
fler 3" clamp/hanger
fler 3" clamp/hanger
fler 3" clamp/hanger
1
1
1
1
C.
C.
C.
C. T
T
T
Tail pipe
ail pipe
ail pipe
ail pipe
1
1
1
1
G
G
G
G.... Rear muf
Rear muf
Rear muf
Rear muffler 3"
fler 3"
fler 3"
fler 3" clamp/hanger
clamp/hanger
clamp/hanger
clamp/hanger
1
1
1
1
D.
D.
D.
D. T
T
T
Turn out
urn out
urn out
urn out
1
1
1
1
H.
H.
H.
H. T
T
T
Turn out 3" clamp/hanger w/shield
urn out 3" clamp/hanger w/shield
urn out 3" clamp/hanger w/shield
urn out 3" clamp/hanger w/shield 1
1
1
1
D
B
G
F
A
E
C
D
B
G
F
A
E
C
D
B
G
F
A
E
C
D
B
G
F
A
E
C
H
H
H
H
T
T
T
T O
O
O
O ST
ST
ST
ST ART
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 JBA
1. Remove and inventory new JBA
1. Remove and inventory new JBA
1. Remove and inventory new JBA
exhaust.
exhaust.
exhaust.
exhaust.
18. Inst
18. Inst
18. Inst
18. Install turn out (D) over end of t
all turn out (D) over end of t
all turn out (D) over end of t
all turn out (D) over end of tail pipe
ail pipe
ail pipe
ail pipe
(C) and tighten clamp/hanger (H) lightly with
(C) and tighten clamp/hanger (H) lightly with
(C) and tighten clamp/hanger (H) lightly with
(C) and tighten clamp/hanger (H) lightly wi
9/16" wrench.
9/16" wrench.
9/16" wrench.
9/16" wrench.
NOTE:
NOTE:
NOTE:
NOTE:
Put anti-seize on
Put anti-seize on
Put anti-seize on
Put anti-seize on
threads.
threads.
threads.
threads.
th
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 tail pipes approximately 3"
ail pipes approximately 3"
ail pipes approximately 3"
ail pipes approximately 3"
behind rear of muf
behind rear of muf
behind rear of muf
behind rear of muffler
fler
fler
fler....
4. S
4. S
4. S
4. Spray lubricant on rear t
pray lubricant on rear t
pray lubricant on rear t
pray lubricant on rear tail pipe hanger
ail pipe hanger
ail pipe hanger
ail pipe hanger
rubber grommet.
rubber grommet.
rubber grommet.
rubber grommet.
8. S
8. S
8. S
8. Spray lubricant on front and rear muf
pray lubricant on front and rear muf
pray lubricant on front and rear muf
pray lubricant on front and rear muffler
fler
fler
fler
hanger rod grommet
hanger rod grommet
hanger rod grommet
hanger rod grommets.
s.
s.
s.
13. Inst
13. Inst
13. Inst
13. Install 3" clamp/hanger (F) into front
all 3" clamp/hanger (F) into front
all 3" clamp/hanger (F) into front
all 3" clamp/hanger (F) into front
muf
muf
muf
muffler hanger rubber grommet and position
fler hanger rubber grommet and position
fler hanger rubber grommet and position
fler hanger rubber grommet and position
clamp over end of end of head pipe (A).
clamp over end of end of head pipe (A).
clamp over end of end of head pipe (A).
clamp over end of end of head pipe (A).
14. Inst
14. Inst
14. Inst
14. Install muf
all muf
all muf
all muffler (B) over head pipe (A)
fler (B) over head pipe (A)
fler (B) over head pipe (A)
fler (B) over head pipe (A)
with JBA logo towards rear of vehicle
with JBA logo towards rear of vehicle
with JBA logo towards rear of vehicle
with JBA logo towards rear of vehicle
making sure muf
making sure muf
making sure muf
making sure muffler bottoms out on slip
fler bottoms out on slip
fler bottoms out on slip
fler bottoms out on slip
joint.
joint.
joint.
joint.
19. Position 3" clamp/hanger (F), level and
19. Position 3" clamp/hanger (F), level and
19. Position 3" clamp/hanger (F), level and
19. Position 3" clamp/hanger (F), level an
tighten completely using 9/16" seep socket.
tighten completely using 9/16" seep socket.
tighten completely using 9/16" seep socket.
tighten completely using 9/16" seep socke
NOTE:
NOTE:
NOTE:
NOTE:
Use anti-seize on threads.
Use anti-seize on threads.
Use anti-seize on threads.
Use anti-seize on threads.
20. Position t
20. Position t
20. Position t
20. Position tail pipe (C) to desired position
ail pipe (C) to desired position
ail pipe (C) to desired position
ail pipe (C) to desired positio
and tighten 3" clamp/hanger (G) completely
and tighten 3" clamp/hanger (G) completely
and tighten 3" clamp/hanger (G) completely
and tighten 3" clamp/hanger (G) complete
using 9/16" deep socket.
using 9/16" deep socket.
using 9/16" deep socket.
using 9/16" deep socket.
d
t.
n
ly
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 t
remove t
remove t
remove tail pipe hanger rod from rubber
ail pipe hanger rod from rubber
ail pipe hanger rod from rubber
ail pipe hanger rod from rubber
grommet.
grommet.
grommet.
grommet.
9. With muf
9. With muf
9. With muf
9. With muffler supported, using channel
fler supported, using channel
fler supported, using channel
fler supported, using channel
lock pliers, remove front and rear muf
lock pliers, remove front and rear muf
lock pliers, remove front and rear muf
lock pliers, remove front and rear muffler
fler
fler
fler
hanger rods from rubber grommet
hanger rods from rubber grommet
hanger rods from rubber grommet
hanger rods from rubber grommets.
s.
s.
s.
15. Inst
15. Inst
15. Inst
15. Install 3" clamp/hanger (G) into rear
all 3" clamp/hanger (G) into rear
all 3" clamp/hanger (G) into rear
all 3" clamp/hanger (G) into rear
muf
muf
muf
muffler rubber grommet
fler rubber grommet
fler rubber grommet
fler rubber grommets with flat bar
s with flat bar
s with flat bar
s with flat bar
towards driver side. Slip clamp/hanger (G)
towards driver side. Slip clamp/hanger (G)
towards driver side. Slip clamp/hanger (G)
towards driver side. Slip clamp/hanger (G)
over end of slip joint of muf
over end of slip joint of muf
over end of slip joint of muf
over end of slip joint of muffler (B). Hand
fler (B). Hand
fler (B). Hand
fler (B). Hand
22.
22.
22.
22. Af
Af
Af
After inst
ter inst
ter inst
ter installation, it is recommended that
allation, it is recommended that
allation, it is recommended that
allation, it is recommended th
all clamp
all clamp
all clamp
all clamps be retightened and joint
s be retightened and joint
s be retightened and joint
s be retightened and joints t
s t
s t
s tack
ack
ack
ack
welded in 3 spot
welded in 3 spot
welded in 3 spot
welded in 3 spots.
s.
s.
s.
21. Rot
21. Rot
21. Rot
21. Rotate turn out (D) to desired position
ate turn out (D) to desired position
ate turn out (D) to desired position
ate turn out (D) to desired position
and tighten 3î clamp/hanger (H) completely
and tighten 3î clamp/hanger (H) completely
and tighten 3î clamp/hanger (H) completely
and tighten 3î clamp/hanger (H) completel
23. Using a sof
23. Using a sof
23. Using a sof
23. Using a soft cloth, remove all print
t cloth, remove all print
t cloth, remove all print
t cloth, remove all prints from
s from
s from
s fro
turn out tip.
turn out tip.
turn out tip.
turn out tip.
at
m
y....
6. Remove t
6. Remove t
6. Remove t
6. Remove tail pipe assembly from rear of
ail pipe assembly from rear of
ail pipe assembly from rear of
ail pipe assembly from rear of
vehicle.
vehicle.
vehicle.
vehicle.
10. Using some form of heat and force,
10. Using some form of heat and force,
10. Using some form of heat and force,
10. Using some form of heat and force,
disengage and remove muf
disengage and remove muf
disengage and remove muf
disengage and remove muffler assembly
fler assembly
fler assembly
fler assembly
without damaging converter pipe.
without damaging converter pipe.
without damaging converter pipe.
without damaging converter pipe.
tighten clamp at this time.
tighten clamp at this time.
tighten clamp at this time.
tighten clamp at this time.
NOTE:
NOTE:
NOTE:
NOTE:
Use anti-seize on threads.
Use anti-seize on threads.
Use anti-seize on threads.
Use anti-seize on threads.
16. Inst
16. Inst
16. Inst
16. Install t
all t
all t
all tail pipe (C) into muf
ail pipe (C) into muf
ail pipe (C) into muf
ail pipe (C) into muffler (B)
fler (B)
fler (B)
fler (B)
from rear of vehicle. Longest end towards
from rear of vehicle. Longest end towards
from rear of vehicle. Longest end towards
from rear of vehicle. Longest end towards
muf
muf
muf
muffler making sure t
fler making sure t
fler making sure t
fler making sure tail pipe bottoms out
ail pipe bottoms out
ail pipe bottoms out
ail pipe bottoms out
in slip joint.
in slip joint.
in slip joint.
in slip joint.
24. Lower vehicle and reatt
24. Lower vehicle and reatt
24. Lower vehicle and reatt
24. Lower vehicle and reattach the negative
ach the negative
ach the negative
ach the negativ
battery cable.
battery cable.
battery cable.
battery cable.
NOTES:
NOTES:
NOTES:
NOTES:
1) It may be necessary to loosen and realign
1) It may be necessary to loosen and realign
1) It may be necessary to loosen and realign
1) It may be necessary to loosen and reali
the sp
the sp
the sp
the spare tire for proper clearance.
are tire for proper clearance.
are tire for proper clearance.
are tire for proper clearance.
gn
e
1
1
1
11. Inst
1. Inst
1. Inst
1. Install head pipe (A) aligning notch
all head pipe (A) aligning notch
all head pipe (A) aligning notch
all head pipe (A) aligning notch
with locating pin.
with locating pin.
with locating pin.
with locating pin.
NOTE:
NOTE:
NOTE:
NOTE:
Make sure pin is
Make sure pin is
Make sure pin is
Make sure pin is
bottomed out in notch.
bottomed out in notch.
bottomed out in notch.
bottomed out in notch.
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 1"
and about 1"
and about 1"
and about 1
rearward when exhaust temperature st
rearward when exhaust temperature st
rearward when exhaust temperature st
rearward when exhaust temperature start to
art to
art to
art
rise.
rise.
rise.
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.
to
"
7. S
7. S
7. S
7. Spray penetrating lubricant on front
pray penetrating lubricant on front
pray penetrating lubricant on front
pray penetrating lubricant on front
head pipe clamp threads at rear of con-
head pipe clamp threads at rear of con-
head pipe clamp threads at rear of con-
head pipe clamp threads at rear of con
verter and remove using a 15mm deep
verter and remove using a 15mm deep
verter and remove using a 15mm deep
verter and remove using a 15mm deep
socket..
socket..
socket..
socket..
12. Inst
12. Inst
12. Inst
12. Install 2-1/2" clamp (E) on front por-
all 2-1/2" clamp (E) on front por-
all 2-1/2" clamp (E) on front por-
all 2-1/2" clamp (E) on front por
tion of head pipe (A).
tion of head pipe (A).
tion of head pipe (A).
tion of head pipe (A). T
T
T
Tighten completely
ighten completely
ighten completely
ighten completely
with 9/16" deep socket.
with 9/16" deep socket.
with 9/16" deep socket.
with 9/16" deep socket.
NOTE:
NOTE:
NOTE:
NOTE:
Use anti-
Use anti-
Use anti-
Use anti
seize on threads.
seize on threads.
seize on threads.
seize on threads.
17. Inst
17. Inst
17. Inst
17. Install 3" clamp/hanger with heat
all 3" clamp/hanger with heat
all 3" clamp/hanger with heat
all 3" clamp/hanger with heat
shield (H) into rear t
shield (H) into rear t
shield (H) into rear t
shield (H) into rear tail pipe rubber grom-
ail pipe rubber grom-
ail pipe rubber grom-
ail pipe rubber grom
met. Slip clamp over end of t
met. Slip clamp over end of t
met. Slip clamp over end of t
met. Slip clamp over end of tail pipe (C).
ail pipe (C).
ail pipe (C).
ail pipe (C).
17041
17041
17041
17041
W
W
W
We
e
e
e recommend taking the truck to a muffler shop and having all slip connections tack welded.
recommend taking the truck to a muffler shop and having all slip connections tack welded.
recommend taking the truck to a muffler shop and having all slip connections tack welded.
recommend taking the truck to a muffler shop and having all slip connections tack welded.
6-20-02
6-20-02
6-20-02
6-20-02