JBA 40-1520 User Manual

INST ALLA TION INSTR UCTIONSINST ALLA TION INSTR UCTIONSINST ALLA TION INSTR UCTIONSINSTALLATION 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.

PartPartPartPart s Lists Lists Lists List

40-1520

A.A.A.A. Head pipeHead pipeHead pipeHead pipe 1111

2002 Dodge Ram quad cab/std. bed 4.7/5.9L V-8

B.B.B.B. MufMufMufMufflerflerflerfler, 24" 1111
C.C.C.C. TTTTail pipeail pipeail pipeail pipe 1111
D.D.D.D. TTTTurn outurn outurn outurn out 1111
E.E.E.E.

GG

GG

2-1/2" clamp 1111
F. 3" clamp hanger
G. 3" clamp hanger
H. 3" clamp

F.
G.
H.

F.
G.
H.

F.
G.
H.

H

D

E

AAA

B

F

EEE

A (For 1520)

C

1111

TTTTOOLS RECOMMENDED:OOLS RECOMMENDED:OOLS RECOMMENDED:OOLS RECOMMENDED:

1111
1111

9/16 deep socket9/16 deep socket9/16 deep socket9/16 deep socket
ratchetratchetratchetratchet
10mm wrench10mm wrench10mm wrench10mm wrench
15mm deep socket15mm deep socket15mm deep socket15mm deep socket
prybarprybarprybarprybar
rubber malletrubber malletrubber malletrubber mallet
spray lubricant or penetrating oilspray lubricant or penetrating oilspray lubricant or penetrating oilspray lubricant or penetrating oil
anti-seizeanti-seizeanti-seizeanti-seize
reciprocating saw or hack sawreciprocating saw or hack sawreciprocating saw or hack sawreciprocating saw or hack saw
ppppair of channel lock pliersair of channel lock pliersair of channel lock pliersair of channel lock pliers

TTTTOOOO STSTSTST ARTARTARTART ::::

ail pipe approximately 1" behind

2. Disconnect negative battery cable and2. Disconnect negative battery cable and2. Disconnect negative battery cable and2. 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.

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 sup­ported, using a reciprocating saw or hackported, using a reciprocating saw or hackported, using a reciprocating saw or hackported, using a reciprocating saw or hack
sawsawsawsaw, cut t, cut t, cut t, cut t
rear mufrear mufrear mufrear muffler clamp and in front of tfler clamp and in front of tfler clamp and in front of tfler clamp and in front of tail pipeail pipeail pipeail pipe

hangerhangerhangerhanger....

4. S4. S4. S4. Spray lubricant on lower holes of frontpray lubricant on lower holes of frontpray lubricant on lower holes of frontpray lubricant on lower holes of front
and rear tand rear tand rear tand rear tail pipe hanger rubber grommetail pipe hanger rubber grommetail pipe hanger rubber grommetail pipe hanger rubber grommets.s.s.s.

1. Remove and inventory new JBA
exhaust.exhaust.exhaust.exhaust.

head pipe (A) using the 2-1/2" clamp (E).

ighten completely with 9/16" deep wall

8. Using some form of heat and force,8. Using some form of heat and force,8. Using some form of heat and force,8. Using some form of heat and force,
disengage and remove mufdisengage and remove mufdisengage and remove mufdisengage and remove muffler withoutfler withoutfler withoutfler without
damaging head pipe.damaging head pipe.damaging head pipe.damaging head pipe.

9.9.9.9. Align notch with locating pin and instAlign notch with locating pin and instAlign notch with locating pin and instAlign notch with locating pin and installallallall
TTTT

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.

7. Remove t7. Remove t7. Remove t7. Remove tail pipe from rear of vehicle.ail pipe from rear of vehicle.ail pipe from rear of vehicle.ail pipe from rear of vehicle.

ail pipe and tighten 3"

13. Inst13. Inst13. Inst13. Install front two hangers on tall front two hangers on tall front two hangers on tall front two hangers on tail pipeail pipeail pipeail pipe
(C) into lower holes of rubber grommet.(C) into lower holes of rubber grommet.(C) into lower holes of rubber grommet.(C) into lower holes of rubber grommet.

14. Inst14. Inst14. Inst14. Install rear tall rear tall rear tall rear tail pipe hanger into rubberail pipe hanger into rubberail pipe hanger into rubberail pipe hanger into rubber
grommet.grommet.grommet.grommet. Align tAlign tAlign tAlign t

clamp (G) completelyclamp (G) completelyclamp (G) completelyclamp (G) completely.... Note:Note:Note:Note: Use anti-Use anti-Use anti-Use anti-

seize on threads.seize on threads.seize on threads.seize on threads.

1" rearward when exhaust temperature

20.20.20.20. AfAfAfAfter instter instter instter installation, it is recommendedallation, it is recommendedallation, it is recommendedallation, it is recommended
that all clampthat all clampthat all clampthat all clamps be retightened and joints be retightened and joints be retightened and joints be retightened and jointssss
ttttack welded in 3 spotack welded in 3 spotack welded in 3 spotack welded in 3 spots.s.s.s.

21. Using a sof21. Using a sof21. Using a sof21. Using a soft cloth, remove all printt cloth, remove all printt cloth, remove all printt cloth, remove all printssss
from turnout tip.from turnout tip.from turnout tip.from turnout tip.

22. Lower vehicle and reatt22. Lower vehicle and reatt22. Lower vehicle and reatt22. Lower vehicle and reattach the nega-ach the nega-ach the nega-ach the nega­tive battery cable.tive battery cable.tive battery cable.tive battery cable.

NOTES:NOTES:NOTES:NOTES:

1) It may be necessary to loosen and1) It may be necessary to loosen and1) It may be necessary to loosen and1) It may be necessary to loosen and
realign the sprealign the sprealign the sprealign the spare tire for proper clear-are tire for proper clear-are tire for proper clear-are tire for proper clear­ance.ance.ance.ance.

2)2)2)2) All exhaust systems will expAll exhaust systems will expAll exhaust systems will expAll exhaust systems will expand aboutand aboutand aboutand about
ststststart to rise.art to rise.art to rise.art to rise.

3) Use3) Use3) Use3) Use Anti-seize on threads of clampAnti-seize on threads of clampAnti-seize on threads of clampAnti-seize on threads of clamps.s.s.s.

ighten clamp (H) completely

using 9/16" deep wall socket.

19.19.19.19. TTTT
Note:Note:Note:Note: Use anti-seize on threads.Use anti-seize on threads.Use anti-seize on threads.Use anti-seize on threads.

11. Using the 3" clamp (F), tighten clamp
completely using 9/16" deep wall socket.

10. With JBA logo facing rear of vehicle,10. With JBA logo facing rear of vehicle,10. With JBA logo facing rear of vehicle,10. With JBA logo facing rear of vehicle,
instinstinstinstall mufall mufall mufall muffler (B) over head pipe (A) mak-fler (B) over head pipe (A) mak-fler (B) over head pipe (A) mak-fler (B) over head pipe (A) mak­ing sure mufing sure mufing sure mufing sure muffler bottoms out on slip joint.fler bottoms out on slip joint.fler bottoms out on slip joint.fler bottoms out on slip joint.

all turn out clamp (H)15. Inst15. Inst15. Inst15. Inst
over end of tover end of tover end of tover end of tail pipe (C) and into rubberail pipe (C) and into rubberail pipe (C) and into rubberail pipe (C) and into rubber
grommet.grommet.grommet.grommet.

5. Using a p5. Using a p5. Using a p5. Using a pair of channel lock pliers,air of channel lock pliers,air of channel lock pliers,air of channel lock pliers,
remove hanger rods from bottom holes ofremove hanger rods from bottom holes ofremove hanger rods from bottom holes ofremove hanger rods from bottom holes of
two rear ttwo rear ttwo rear ttwo rear tail pipe rubber grommetail pipe rubber grommetail pipe rubber grommetail pipe rubber grommets.s.s.s.

6. Using a p6. Using a p6. Using a p6. Using a pair of channel lock pliers,air of channel lock pliers,air of channel lock pliers,air of channel lock pliers,
remove front tremove front tremove front tremove front tail pipe hanger rod fromail pipe hanger rod fromail pipe hanger rod fromail pipe hanger rod from
bottom hole in rubber grommet.bottom hole in rubber grommet.bottom hole in rubber grommet.bottom hole in rubber grommet.

12. Inst12. Inst12. Inst12. Install tall tall tall tail pipe (C) from rear of vehi-ail pipe (C) from rear of vehi-ail pipe (C) from rear of vehi-ail pipe (C) from rear of vehi-

cle with double hanger towards mufcle with double hanger towards mufcle with double hanger towards mufcle with double hanger towards mufflerflerflerfler....

ate to desired position approx. 1"

18. Inst18. Inst18. Inst18. Install turn out (D) to end of tall turn out (D) to end of tall turn out (D) to end of tall turn out (D) to end of tail pipeail pipeail pipeail pipe
(C) rot(C) rot(C) rot(C) rot

from bodyfrom bodyfrom bodyfrom body....

17039a17039a17039a17039a

WWWeee recommend trecommend trecommend t aking the truck to a muffler shop and having all slip connections tack welded.We

7-3-02

40-1521

2002 Dodge Ram std. cab/short bed 4.7/5.9L V-8

A (For 1521)