JBA 40-3027 - Manual

INSTALLATION INSTRUCTIONS
**Ins tallation recommendation:
J B A recommends in mos t cas es that the vehicle be taken to a reputable exhaus t s hop.
40-3027
F
02-04 Chevrolet Trailblazer
I-6 4.2L 2/4 WD
T T T T OOLS R E C OMME NDE D: P arts Lis t
ratchet A. Head pipe with hanger 1
9/16" deep socket B. Muffler 22" 1
15mm deep socket C. Tail pipe with hanger 1
pair of channel lock pliers D. Tip with resonator 1
reciprocating saw or hack saw E. Front muf fler clamp 3" 2
rubber mallet F... Rear muffler clamp/hanger 3" 1
spray lubricant or penetrating oil G. 10mm nut 2
anti-seize H. 10mm flat washer 2
prybar I. 10mm lock washer 2
A
B C
D
E E
Start:
1. Remove and inventory new
JBA exhaust system.
2. Disconnect negative battery
cable and allow vehicle to cool.
7. Install the new JBA muffler
(B) onto the intermediate pipe
(A) and then position the 3"
clamp over slip connection.
11. Insert the tail pipe hanger
into the rubber grommet behind
the muffler.
.
3. With vehicle raised and
properly supported, using a
reciprocating saw or hack saw,
cut the tail pipe approximately 3"
behind the muffler.
4. Remove the nuts attaching
8. Spray lubricant on the rear
hanger grommet. Remove the
rear hanger from the grommet
12. Slip the tailpipe (C) together
with the muffler (B) outlet. Attach
the 3" clamp over the
connection.
16. Check for adequate
clearance from rear bumper and
tighten 3" clamp with hanger.
17. Using a soft cloth, remove
all prints from exhaust tip.
18. Check all clamps and
connections for proper fit and
alignment. Double check all
clamps are tightened.
18. Check all clamps and
connections for proper fit and
alignment. Double check all
clamps are tightened.
the intermediate pipe to the
catalytic converter assembly
using a 9/16" deep socket. using a pair of channel lock
pliers.
13. Slip 3" clamp with hanger
(X) over the end of tail pipe (C).
Install hanger into rear hanger
NOTES:
1.) It may be neccessary to
loosen and realign the spare tire
for proper clearance.
2.) All exhaust systems expand
5. Spray lubricant on the
intermediate pipe hanger
grommet and then remove the
pipe.
6. Install the new intermediate
pipe (A) into the hanger
grommet.
9. Remove the tail pipe and rear
muffler assembly from the rear
of the vehicle.
grommet as shown.
14. Install the tip with resonator
(D) onto the end of the the tail
pipe (C).
about 1" rearward when exhaust
temperature rises.
3. Use anti-seize on threads of
clamps.
7. Using a 9/16" deep socket,
attach the intermediate pipe to
the catalytic converter assembly.
10. Install the new tail pipe (C)
over the rear axle with the
hanger closest to the muffler. 15. Align the tip and resonator
and slide the 3" clamp with
hanger over the slip connection.
We recommend taking the truck to a muffler s hop and having all s lip connections tack welded. 4.20.07