JBA 40-1510 User Manual

INSTALLATION INSTRUCTIONS

**Inst allation recommendation:

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

40-1510

1998-2000 Dodge Durango
V8-5.2L, 5.9L

TOOLS RECOMMENDED:

9/16 deep socket
3/8" ratchet
rubber mallet
spray lubricant or penetrating oil
anti-seize
reciprocating saw or hack saw
pair of channel lock pliers, 10"

TO START:

1. Remove and inventory new JBA
exhaust.

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

Part s List

A. Head pipe
B. Muffler, oval
C. Tail pipe
D. Turn out
E. 2-1/2" clamp

E

F

A

F. 3" clamp
G. 3" clamp/hanger
H. 3" clamp

B

G

C

1
1
1
1
1
1
1
1

H

D

3. With vehicle raised and properly sup­ported, spray lubricant on the two rear
muffler hanger rubber grommet’s lower
hole.

4. Spray lubricant on rear tail pipe
hanger rubber grommet’s lower hole.

5. Using a pair of channel lock pliers,
remove rear tail pipe hanger from lower
hole in rubber grommet.

7. Remove tail pipe from rear of vehicle.

8. Using a pair of channel lock pliers,
remove both rear muffler hangers from
lower holes in rubber grommets.

cut 2-3/8"

1998-99 vehicle

cut 2-3/8”

2000 vehicle

9. With muffler properly supported, using
a reciprocating saw or hacksaw, cut muf­fler off 2-3/8" away from muffler face.

10. Remove muffler.

11. Install head pipe (A) over stock
exhaust. Slip on to about 1-1/2".

13. Install rear muffler clamp/hanger (G)
thru the lower holes in rubber grommets.
The two bend rod should go to the pas­senger side.

14. With JBA logo facing rear of vehicle,
install muffler (B) over head pipe (A) mak­ing sure muffler bottoms out on slip joint.

15. Put some anti seize on threads of 3"
clamp (F) and install on front of muffler
slip joint with a 9/16" deep wall socket.
Tighten completely.

16. Put some anti seize on threads of
clamp/hanger (G) and install over end of
muffler. Hand tighten nuts at this time.

17. Install tail pipe (C) hanger towards
rear of vehicle from rear of vehicle and
slip into muffler (B).

18. Slip rear tail pipe hanger into rubber
grommet.

19. Position tail pipe (C) so hanger is not
cocked at an angle.

22. Put some anti seize on threads of 3"
clamp (H) and install over slip joint.

23. Tighten until snug using a 9/16" deep
wall socket.

24. Rotate turn out to desire position
making sure you check clearance on
body. Tighten clamp (H) completely.

25. After installation, it is recommended
that all clamps be retightened.

26. Tack weld all slip connections in
three spot s.

27. Using a soft cloth, remove all prints
from turnout tip (D).

28. Lower vehicle and reattach the nega­tive battery cable.

NOTES:

1) It may be necessary to loosen and
realign the spare tire for proper clear­ance.

2) All exhaust systems will expand about
1" rearward when exhaust temperature
start to rise.

3) Use Anti-seize on threads of clamps.

6. Using a reciprocating saw or hacksaw,
cut tail pipe approximately 3" behind rear
of muffler.

20. Tighten clamp/hanger (G) complete­ly making sure tail pipe (C) is bottomed
out on muffler (B) slip joint.

12. Put some anti-seize on threads of the
2-1/2" clamp (E) and install on front of
head pipe. With 9/16" deep socket, tight­en completely.

21. Install turnout (D) over tail pipe (C).

17040b
8-26-02