JBA 40-1501 User Manual

INSTALLATION INSTRUCTIONS

* Installation Recommendation: JBA recommends in most cases that the vehicle be taken to a reputable exhaust shop.

40-1501

2000-2006 Jeep Wrangler 2.5/4.0L TJ 4wd

RECOMMENDED TOOLS:

pry bar ratchet 15mm deep socket channel lock pliers anti-seize spray lubricant or penetrating oil

PARTS LIST:

A. Tail pipe 1 B. Muffler 1 C. Intermediate pipe 1 D. Rear muffler clamp hanger 1 E. U-bolt clamp 1

TO START:

1. Remove and inventory JBA exhaust.

2. Disconnect negative battery cable and allow vehicle exhaust to cool.

3. Spray fasteners with penetrating oil.

4. Separate muffler and tailpipe by cutting tailpipe behind muffler with reciprocating saw or similar.

7. Install new intermediate pipe with hardware provided.

14. Tack weld all slip connections in three spots.

15. Lower the vehicle and reattach th negative battery cable.

NOTES:

1) All exhaust systems will expand ab 1" rearward when exhaust temperat start to rise.

10. Slip tailpipe over axle and E-brake cable. Inser into rear of muffler.v

2) Use Anti-seize on threads of clamp

out

ures

5. Spray lubricant on rubber isolators, slip tailpipe hangers out of rubber isolators, remove tailpipe from vehicle.

8. Slip a U-bolt clamp onto the I-pipe. Slip muffler onto I-pipe with offset towards the front, and the muffler extending towards the driveshaft. Align muffler to be flat.

9. Slip rear muffler clamp hanger into rubber isolator. Position onto muffler, snug lightly.

11. Insert tailpipe hanger into rubber isolator.

12. Align tailpipe to clear shock, fuel tank, and suspension

6. Unbolt flange in front of muffler. Remove muffler from vehicle

13. Secure all fasteners and clamps. Muffler slip joints should be tack welded.

Rev 2.19.06