JBA 40-3003 User Manual
Installation instructions, Inst, Gm pickup

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.
40-3003
GM Pickup
GM Pickup
GM Pickup
GM Pickup
96-98 V8-5.7L
96-98 V8-5.7L
96-98 V8-5.7L
96-98 V8-5.7L S
S
S
Sttttd. cab, S
d. cab, S
d. cab, S
d. cab, Sttttd. bed
d. bed
d. bed
d. bed
Part
Part
Part
Part s List
s List
s List
s List
T
T
T
T OOLS RECOMMENDED:
OOLS RECOMMENDED:
OOLS RECOMMENDED:
OOLS RECOMMENDED:
A.
A.
A.
A. Head pipe with hanger
Head pipe with hanger
Head pipe with hanger
Head pipe with hanger
1
1
1
1
reciprocating saw or hack saw
reciprocating saw or hack saw
reciprocating saw or hack saw
reciprocating saw or hack saw
B.
B.
B.
B. Muf
Muf
Muf
Muffler 24"
fler 24"
fler 24"
fler 24"
1
1
1
1
prybar
prybar
prybar
prybar
C.
C.
C.
C. T
T
T
Tail pipe with hanger
ail pipe with hanger
ail pipe with hanger
ail pipe with hanger
1
1
1
1
rubber mallet
rubber mallet
rubber mallet
rubber mallet
D.
D.
D.
D. T
T
T
Turn out
urn out
urn out
urn out
1
1
1
1
ratchet
ratchet
ratchet
ratchet
E.
E.
E.
E. Front muf
Front muf
Front muf
Front muffler clamp 3"
fler clamp 3"
fler clamp 3"
fler clamp 3"
1
1
1
1
15mm deep socket
15mm deep socket
15mm deep socket
15mm deep socket
F
F
F
F.... Rear muf
Rear muf
Rear muf
Rear muffler clamp/hanger 3"
fler clamp/hanger 3"
fler clamp/hanger 3"
fler clamp/hanger 3"
1
1
1
1
9/16 box wrench or socket
9/16 box wrench or socket
9/16 box wrench or socket
9/16 box wrench or socket
G
G
G
G.... T
T
T
Turn out clamp 3"
urn out clamp 3"
urn out clamp 3"
urn out clamp 3"
1
1
1
1
7/8" open end wrench
7/8" open end wrench
7/8" open end wrench
7/8" open end wrench
p
p
p
pair of channel lock pliers
air of channel lock pliers
air of channel lock pliers
air of channel lock pliers
13mm socket
13mm socket
13mm socket
13mm socket
C
C
C
C
anti-seize
anti-seize
anti-seize
anti-seize
imp
imp
imp
impact wrench
act wrench
act wrench
act wrench
D
B
G
F
E
A
D
B
G
F
E
A
D
B
G
F
E
A
D
B
G
F
E
A
T
T
T
T O
O
O
O ST
ST
ST
ST ART
ART
ART
ART ::::
spray lubricant or penetrating oil
spray lubricant or penetrating oil
spray lubricant or penetrating oil
spray lubricant or penetrating oil
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.
9. Remove three nut
9. Remove three nut
9. Remove three nut
9. Remove three nuts on three bolt flange
s on three bolt flange
s on three bolt flange
s on three bolt flange
using 15mm socket.
using 15mm socket.
using 15mm socket.
using 15mm socket. Y
Y
Y
You may want to use
ou may want to use
ou may want to use
ou may want to use
some penetrating oil.
some penetrating oil.
some penetrating oil.
some penetrating oil.
15. With muf
15. With muf
15. With muf
15. With muffler (B) in place, inst
fler (B) in place, inst
fler (B) in place, inst
fler (B) in place, install muf-
all muf-
all muf-
all muf
fler clamp (E) on slip fit joint. Position 1/4"
fler clamp (E) on slip fit joint. Position 1/4"
fler clamp (E) on slip fit joint. Position 1/4"
fler clamp (E) on slip fit joint. Position 1/4"
from lip.
from lip.
from lip.
from lip. T
T
T
Tighten clamp completely with
ighten clamp completely with
ighten clamp completely with
ighten clamp completely with
9/16" deep wall socket. NOTE: Use some
9/16" deep wall socket. NOTE: Use some
9/16" deep wall socket. NOTE: Use some
9/16" deep wall socket. NOTE: Use some
anti-seize on all threads.
anti-seize on all threads.
anti-seize on all threads.
anti-seize on all threads.
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 3"
ail pipe approximately 3"
ail pipe approximately 3"
ail pipe approximately 3"
behind rear muf
behind rear muf
behind rear muf
behind rear muffler hanger
fler hanger
fler hanger
fler hanger....
10. Using a p
10. Using a p
10. Using a p
10. Using a pair of channel lock pliers,
air of channel lock pliers,
air of channel lock pliers,
air of channel lock pliers,
remove front and rear muf
remove front and rear muf
remove front and rear muf
remove front and rear muffler hanger rods
fler hanger rods
fler hanger rods
fler hanger rods
from bottom holes of grommet
from bottom holes of grommet
from bottom holes of grommet
from bottom holes of grommets.
s.
s.
s.
Note:
Note:
Note:
Note:
support muf
support muf
support muf
support muffler before st
fler before st
fler before st
fler before starting.
arting.
arting.
arting.
16. Inst
16. Inst
16. Inst
16. Install rear muf
all rear muf
all rear muf
all rear muffler clamp/hanger (F)
fler clamp/hanger (F)
fler clamp/hanger (F)
fler clamp/hanger (F)
over slip joint on rear of muf
over slip joint on rear of muf
over slip joint on rear of muf
over slip joint on rear of muffler
fler
fler
fler. Do not
. Do not
. Do not
. Do not
tighten at this time.
tighten at this time.
tighten at this time.
tighten at this time.
22. Position rear muf
22. Position rear muf
22. Position rear muf
22. Position rear muffler clamp/hanger (F)
fler clamp/hanger (F)
fler clamp/hanger (F)
fler clamp/hanger (F)
1/4" from lip on slip joint and tighten com-
1/4" from lip on slip joint and tighten com-
1/4" from lip on slip joint and tighten com-
1/4" from lip on slip joint and tighten com
pletely with 9/16" deep wall socket. Note:
pletely with 9/16" deep wall socket. Note:
pletely with 9/16" deep wall socket. Note:
pletely with 9/16" deep wall socket. Note:
Use anti-seize on threads.
Use anti-seize on threads.
Use anti-seize on threads.
Use anti-seize on threads.
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
grommet.
grommet.
grommet.
grommet.
1
1
1
11. Remove muf
1. Remove muf
1. Remove muf
1. Remove muffler assembly pulling
fler assembly pulling
fler assembly pulling
fler assembly pulling
towards rear of vehicle. Note: use care not
towards rear of vehicle. Note: use care not
towards rear of vehicle. Note: use care not
towards rear of vehicle. Note: use care not
to damage gasket on three bolt flange.
to damage gasket on three bolt flange.
to damage gasket on three bolt flange.
to damage gasket on three bolt flange.
17. Slip clamp/hanger (F) into lower hole
17. Slip clamp/hanger (F) into lower hole
17. Slip clamp/hanger (F) into lower hole
17. Slip clamp/hanger (F) into lower hole
on rubber grommet.
on rubber grommet.
on rubber grommet.
on rubber 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 rod from bottom hole of
remove hanger rod from bottom hole of
remove hanger rod from bottom hole of
remove hanger rod from bottom hole of
grommet.
grommet.
grommet.
grommet.
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.
8. Remove oxygen sensor with 7/8" open
8. Remove oxygen sensor with 7/8" open
8. Remove oxygen sensor with 7/8" open
8. Remove oxygen sensor with 7/8" open
end wrench.
end wrench.
end wrench.
end wrench.
7. S
7. S
7. S
7. 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 grommet
hanger grommet
hanger grommet
hanger grommets.
s.
s.
s.
12. Inst
12. Inst
12. Inst
12. Install head pipe (A) with three bolt
all head pipe (A) with three bolt
all head pipe (A) with three bolt
all head pipe (A) with three bolt
flange. Inst
flange. Inst
flange. Inst
flange. Install hanger through lower hole
all hanger through lower hole
all hanger through lower hole
all hanger through lower hole
in rubber grommet.
in rubber grommet.
in rubber grommet.
in rubber grommet. T
T
T
Tighten three nut
ighten three nut
ighten three nut
ighten three nuts
s
s
s
using 15mm socket.
using 15mm socket.
using 15mm socket.
using 15mm socket.
Note:
Note:
Note:
Note:
we recom-
we recom-
we recom-
we recom
mend using anti-seize on threads.
mend using anti-seize on threads.
mend using anti-seize on threads.
mend using anti-seize on threads.
13. Inst
13. Inst
13. Inst
13. Install oxygen sensor using 7/8"
all oxygen sensor using 7/8"
all oxygen sensor using 7/8"
all oxygen sensor using 7/8"
wrench.
wrench.
wrench.
wrench.
14. Slip muf
14. Slip muf
14. Slip muf
14. Slip muffler (B) on head pipe approxi-
fler (B) on head pipe approxi-
fler (B) on head pipe approxi-
fler (B) on head pipe approxi
mately 2". Note:
mately 2". Note:
mately 2". Note:
mately 2". Note: Y
Y
Y
You may have to t
ou may have to t
ou may have to t
ou may have to tap it in
ap it in
ap it in
ap it in
with a rubber mallet. Make sure JBA logo
with a rubber mallet. Make sure JBA logo
with a rubber mallet. Make sure JBA logo
with a rubber mallet. Make sure JBA logo
is to the rear
is to the rear
is to the rear
is to the rear....
18. Inst
18. Inst
18. Inst
18. Install t
all t
all t
all tail pipe (C) from rear into slip
ail pipe (C) from rear into slip
ail pipe (C) from rear into slip
ail pipe (C) from rear into slip
joint on muf
joint on muf
joint on muf
joint on muffler (B). Slip approx. 2".
fler (B). Slip approx. 2".
fler (B). Slip approx. 2".
fler (B). Slip approx. 2".
19. Slip rear t
19. Slip rear t
19. Slip rear t
19. Slip rear tail pipe (C) hanger into
ail pipe (C) hanger into
ail pipe (C) hanger into
ail pipe (C) hanger into
lower hole in rubber grommet.
lower hole in rubber grommet.
lower hole in rubber grommet.
lower hole in rubber grommet.
20. Position t
20. Position t
20. Position t
20. Position tail pipe (C) so hanger is not
ail pipe (C) so hanger is not
ail pipe (C) so hanger is not
ail pipe (C) so hanger is not
cocked at an angle, and rubber grommet
cocked at an angle, and rubber grommet
cocked at an angle, and rubber grommet
cocked at an angle, and rubber grommet
is angled forward.
is angled forward.
is angled forward.
is angled forward.
21. Inspect clearance around rear-end
21. Inspect clearance around rear-end
21. Inspect clearance around rear-end
21. Inspect clearance around rear-end
shock and sp
shock and sp
shock and sp
shock and spare tire.
are tire.
are tire.
are tire.
24. Using a sof
24. Using a sof
24. Using a sof
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.
25. Lower vehicle and reatt
25. Lower vehicle and reatt
25. Lower vehicle and reatt
25. 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
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 D,
s D,
s D,
s D,
E and F
E and F
E and F
E and F....
23. Slip turn out clamp (G) onto t
23. Slip turn out clamp (G) onto t
23. Slip turn out clamp (G) onto t
23. Slip turn out clamp (G) onto tail pipe.
ail pipe.
ail pipe.
ail pipe.
Slip turn out (D) on t
Slip turn out (D) on t
Slip turn out (D) on t
Slip turn out (D) on tail pipe (C) approx.
ail pipe (C) approx.
ail pipe (C) approx.
ail pipe (C) approx.
1-1/2î. Rot
1-1/2î. Rot
1-1/2î. Rot
1-1/2î. Rotate tip to desired position leav-
ate tip to desired position leav-
ate tip to desired position leav-
ate tip to desired position leav
ing clearance from body
ing clearance from body
ing clearance from body
ing clearance from body. Position clamp
. Position clamp
. Position clamp
. Position clamp
(G) with threads in an upward position.
(G) with threads in an upward position.
(G) with threads in an upward position.
(G) with threads in an upward position.
T
T
T
Tighten completely with 9/16" deep wall
ighten completely with 9/16" deep wall
ighten completely with 9/16" deep wall
ighten completely with 9/16" deep wall
socket. Note: use anti-seize on threads.
socket. Note: use anti-seize on threads.
socket. Note: use anti-seize on threads.
socket. Note: use anti-seize on threads.
17092
17092
17092
17092
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.
4/17/07