JBA 40-2522 User Manual
Installation instructions, Part, Part parts list s list s list s list

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.
Part
Part
Part
Parts List
s List
s List
s List
40-2522
A.
A.
A.
A. Head pipe
Head pipe
Head pipe
Head pipe
1
1
1
1
E.
E.
E.
E. 2-1/2" clamp
2-1/2" clamp
2-1/2" clamp
2-1/2" clamp
1
1
1
1
B.
B.
B.
B. 24" muf
24" muf
24" muf
24" muffler
fler
fler
fler
1
1
1
1
F
F
F
F.... 3" clamp
3" clamp
3" clamp
3" clamp
1
1
1
1
1999-00 Ford F-150 Ext/S
1999-00 Ford F-150 Ext/S
1999-00 Ford F-150 Ext/S
1999-00 Ford F-150 Ext/Sttttd
d
d
d 2/4 WD
2/4 WD
2/4 WD
2/4 WD
C.
C.
C.
C. T
T
T
Tail pipe
ail pipe
ail pipe
ail pipe
1
1
1
1
G
G
G
G.... 3" muf
3" muf
3" muf
3" muffler clamp/hanger
fler clamp/hanger
fler clamp/hanger
fler 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. 3" t
3" t
3" t
3" tail pipe clamp
ail pipe clamp
ail pipe clamp
ail pipe clamp
1
1
1
1
E
E
E
E
V8-4.6L, V8- 5.4L
V8-4.6L, V8- 5.4L
V8-4.6L, V8- 5.4L
V8-4.6L, V8- 5.4L
F
F
F
F
1998 5.4L
1998 5.4L
1998 5.4L
1998 5.4L V8
V8
V8
V8
G
G
G
G
T
T
T
TOOLS RECOMMENDED:
OOLS RECOMMENDED:
OOLS RECOMMENDED:
OOLS RECOMMENDED:
H
H
H
H
ratchet
ratchet
ratchet
ratchet
rubber mallet
rubber mallet
rubber mallet
rubber mallet
9/16 deep socket
9/16 deep socket
9/16 deep socket
9/16 deep socket
spray lubricant or penetrating
spray lubricant or penetrating
spray lubricant or penetrating
spray lubricant or penetrating
15mm socket
15mm socket
15mm socket
15mm socket
oil
oil
oil
oil
p
p
p
pair of channel lock pliers
air of channel lock pliers
air of channel lock pliers
air of channel lock pliers
prybar
prybar
prybar
prybar
reciprocating saw or hack
reciprocating saw or hack
reciprocating saw or hack
reciprocating saw or hack
imp
imp
imp
impact wrench
act wrench
act wrench
act wrench
saw
saw
saw
saw
anti-seize
anti-seize
anti-seize
anti-seize
8mm wrench
8mm wrench
8mm wrench
8mm wrench
D
D
D
D
A
A
A
A
T
T
T
TO
O
O
O ST
ST
ST
START
ART
ART
ART::::
B
C
B
C
B
C
B
C
2. Disconnect negative battery cable with
2. Disconnect negative battery cable with
2. Disconnect negative battery cable with
2. Disconnect negative battery cable with
8 mm wrench and allow vehicle exhaust
8 mm wrench and allow vehicle exhaust
8 mm wrench and allow vehicle exhaust
8 mm wrench and allow vehicle exhaust
to cool.
to cool.
to cool.
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.
13. Install muffler.
19. Inst
19. Inst
19. Inst
19. Install rear t
all rear t
all rear t
all rear tail pipe hanger into
ail pipe hanger into
ail pipe hanger into
ail pipe hanger into
lower hole of rubber grommet. Rot
lower hole of rubber grommet. Rot
lower hole of rubber grommet. Rot
lower hole of rubber grommet. Rotate
ate
ate
ate
ttttail pipe (C) to align rear hanger rod.
ail pipe (C) to align rear hanger rod.
ail pipe (C) to align rear hanger rod.
ail pipe (C) to align rear hanger rod.
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 3î
ail pipe approximately 3î
ail pipe approximately 3î
ail pipe approximately 3î
behind muf
behind muf
behind muf
behind muffler
fler
fler
fler....
8. Using a p
8. Using a p
8. Using a p
8. Using a pair of channel lock pliers,
air of channel lock pliers,
air of channel lock pliers,
air of channel lock pliers,
remove rubber grommet
remove rubber grommet
remove rubber grommet
remove rubber grommets completely and
s completely and
s completely and
s completely and
save.
save.
save.
save.
They will be reinst
They will be reinst
They will be reinst
They will be reinstalled
alled
alled
alled
....
14. Slip muf
14. Slip muf
14. Slip muf
14. Slip muffler hanger (G) over end of
fler hanger (G) over end of
fler hanger (G) over end of
fler hanger (G) over end of
20.
20.
20.
20. T
T
T
Tighten 3" clamp/hanger (G) com-
ighten 3" clamp/hanger (G) com-
ighten 3" clamp/hanger (G) com-
ighten 3" clamp/hanger (G) com-
pletely with 9/16" deep socket.
pletely with 9/16" deep socket.
pletely with 9/16" deep socket.
pletely with 9/16" deep socket.
muf
muf
muf
muffler (B) and hand tighten only
fler (B) and hand tighten only
fler (B) and hand tighten only
fler (B) and hand tighten only....
15. Rot
15. Rot
15. Rot
15. Rotate head pipe (A) to desired posi-
ate head pipe (A) to desired posi-
ate head pipe (A) to desired posi-
ate head pipe (A) to desired posi-
tion.
tion.
tion.
tion.
NOTE:
NOTE:
NOTE:
NOTE:
use anti-seize on threads.
use anti-seize on threads.
use anti-seize on threads.
use anti-seize on threads.
(C).
).
4. S
4. S
4. S
4. Spray lubricant on lower rubber hanger
pray lubricant on lower rubber hanger
pray lubricant on lower rubber hanger
pray lubricant on lower rubber hanger
grommet on rear section of t
grommet on rear section of t
grommet on rear section of t
grommet on rear section of tail pipe.
ail pipe.
ail pipe.
ail pipe.
5. Using channel lock pliers, remove rear
5. Using channel lock pliers, remove rear
5. Using channel lock pliers, remove rear
5. Using channel lock pliers, remove rear
ttttail pipe hanger rod
ail pipe hanger rod
ail pipe hanger rod
ail pipe hanger rod from lower hole of
from lower hole of
from lower hole of
from lower hole of
rubber grommet.
rubber grommet.
rubber grommet.
rubber grommet.
9. Lubricate front muf
9. Lubricate front muf
9. Lubricate front muf
9. Lubricate front muffler clamp bolt
fler clamp bolt
fler clamp bolt
fler clamp bolts and
s and
s and
s and
using a 15 mm socket, loosen and
using a 15 mm socket, loosen and
using a 15 mm socket, loosen and
using a 15 mm socket, loosen and
remove clamp.
remove clamp.
remove clamp.
remove clamp.
10. Using some form of force, or heat,
10. Using some form of force, or heat,
10. Using some form of force, or heat,
10. Using some form of force, or heat,
disengage and remove muf
disengage and remove muf
disengage and remove muf
disengage and remove muffler
fler
fler
fler....
Note:
Note:
Note:
Note:
Do Not Damage stock head
Do Not Damage stock head
Do Not Damage stock head
Do Not Damage stock headpipe.
pipe.
pipe.
pipe.
16. Put anti-seize on threads of 2"
16. Put anti-seize on threads of 2"
16. Put anti-seize on threads of 2"
16. Put anti-seize on threads of 2"
clamp (E) and inst
clamp (E) and inst
clamp (E) and inst
clamp (E) and install on front of head-
all on front of head-
all on front of head-
all on front of head-
pipe with 9/16" deep wall socket.
pipe with 9/16" deep wall socket.
pipe with 9/16" deep wall socket.
pipe with 9/16" deep wall socket.
T
T
T
Tightening completely
ightening completely
ightening completely
ightening completely....
Note:
Note:
Note:
Note:
make sure clamp is on the rear
make sure clamp is on the rear
make sure clamp is on the rear
make sure clamp is on the rear
side of pin as close as possible.
side of pin as close as possible.
side of pin as close as possible.
side of pin as close as possible.
17.
17.
17.
17. Put anti-seize on 3" clamp (F) and
Put anti-seize on 3" clamp (F) and
Put anti-seize on 3" clamp (F) and
Put anti-seize on 3" clamp (F) and
inst
inst
inst
install to front slip of muf
all to front slip of muf
all to front slip of muf
all to front slip of muffler
fler
fler
fler. Position
. Position
. Position
. Position
clamp 1/2" from lip and tighten completely
clamp 1/2" from lip and tighten completely
clamp 1/2" from lip and tighten completely
clamp 1/2" from lip and tighten completely
with 9/16" socket.
with 9/16" socket.
with 9/16" socket.
with 9/16" socket.
22. Rot
22. Rot
22. Rot
22. Rotate turn out (D) to desired posi-
ate turn out (D) to desired posi-
ate turn out (D) to desired posi-
ate turn out (D) to desired posi-
tion, leaving clearance from body
tion, leaving clearance from body
tion, leaving clearance from body
tion, leaving clearance from body....
Position 3" clamp (H) over slip joint and
Position 3" clamp (H) over slip joint and
Position 3" clamp (H) over slip joint and
Position 3" clamp (H) over slip joint and
tighten completely using 9/16" deep
tighten completely using 9/16" deep
tighten completely using 9/16" deep
tighten completely using 9/16" deep
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.
21. Slip 3" clamp (H) over end of t
21. Slip 3" clamp (H) over end of t
21. Slip 3" clamp (H) over end of t
21. Slip 3" clamp (H) over end of tail pipe (C).
ail pipe (C).
ail pipe (C).
ail pipe
Inst
Inst
Inst
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 (C).
ail pipe (C).
ail pipe (C).
ail pipe (C
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.
1
1
1
11. Inst
1. Inst
1. Inst
1. Install JBA head
all JBA head
all JBA head
all JBA head pipe (A), aligning
pipe (A), aligning
pipe (A), aligning
pipe (A), aligning
notch with locating pin.
notch with locating pin.
notch with locating pin.
notch with locating pin.
Note:
Note:
Note:
Note:
Make sure
Make sure
Make sure
Make sure
pin is bottomed out in notch.
pin is bottomed out in notch.
pin is bottomed out in notch.
pin is bottomed out in notch.
7. S
7. S
7. S
7. Spray lubricant on all holes of muf
pray lubricant on all holes of muf
pray lubricant on all holes of muf
pray lubricant on all holes of muffler
fler
fler
fler
hanger grommet
hanger grommet
hanger grommet
hanger grommets.
s.
s.
s.
12. Reinst
12. Reinst
12. Reinst
12. Reinstall two rubber grommet
all two rubber grommet
all two rubber grommet
all two rubber grommets to
s to
s to
s to
stock hangers and inst
stock hangers and inst
stock hangers and inst
stock hangers and install muf
all muf
all muf
all muffler hang-
fler hang-
fler hang-
fler hang-
er (G) thru lower holes of grommet.
er (G) thru lower holes of grommet.
er (G) thru lower holes of grommet.
er (G) thru lower holes of grommet.
Note:
Note:
Note:
Note:
longer end of hanger is to go on
longer end of hanger is to go on
longer end of hanger is to go on
longer end of hanger is to go on
drivers side, looking from rear
drivers side, looking from rear
drivers side, looking from rear
drivers side, looking from rear....
18. Inst
18. Inst
18. Inst
18. Install t
all t
all t
all tail pipe (C) from rear of vehicle,
ail pipe (C) from rear of vehicle,
ail pipe (C) from rear of vehicle,
ail pipe (C) from rear of vehicle,
and slip into muf
and slip into muf
and slip into muf
and slip into muffler
fler
fler
fler....
Note:
Note:
Note:
Note:
make sure that
make sure that
make sure that
make sure that
the end of the t
the end of the t
the end of the t
the end of the tail pipe with the hanger is
ail pipe with the hanger is
ail pipe with the hanger is
ail pipe with the hanger is
at the rear of the vehicle.
at the rear of the vehicle.
at the rear of the vehicle.
at the rear of the vehicle.
23. Reatt
23. Reatt
23. Reatt
23. Reattach the negative battery cable.
ach the negative battery cable.
ach the negative battery cable.
ach the negative battery cable.
24.
24.
24.
24. 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 3 spot
ack welded in 3 spot
ack welded in 3 spot
ack welded in 3 spots
s
s
s
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
1î rearward when exhaust temperature
1î rearward when exhaust temperature
1î rearward when exhaust temperature
1î rearward when exhaust temperature
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.
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.
6.13.06