JBA 40-1666 User Manual
INSTALLATION INSTRUCTIONS
** Installation recommendation: JBA recommends in most case that the vehicle be taken to a reputable exhaust shop for installation.
40-1665
08-09 Dodge Challenger SRT8 6.1L - 3 inch system
40-1666
2009 Dodge Challenger 5.7L - 2.5 inch system
F
B
F
E
Recommended Tools:
15mm deep socket
9/16 deep socket
13mm deep socket
Pry bar
WD-40 or equivalent
Start:
1. Remove and inventory new JBA
exhaust system.
2. Disconnect negative battery
cable and allow vehicle to cool.
3. With the vehicle raised and
properly supported, unbolt the factory cross member that runs under
the drive shaft and swing it out of
the way.
Parts List Qty.
A. X-pipe 1
B. JBA mufer 2
C. Passenger side tail pipe with tip 1
D. Driver side tail pipe with tip 1
E. Sure Seal™ clamp 2
F. U-bolt clamp 6
G. Tip Adapter 2
9. Slip the new JBA X-pipe (A) over
the end of the catalytic converter
assembly.
10. Align the X-pipe (A) so that it is
at and even with the off-set exit on
the passenger side. Then tighten
the Sure-Seal™ clamps (E) over
the connection to the cat. assembly.
G
F
F
C
16. Install the supplied U-bolt
clamps (F) over the end of the muf-
ers (B).
17. Slip tailpipe tip adapters (G)
onto the end of the tailpipe. Connect hangers.
G
A
E
F
B
21. Tighten clamps, Tack weld slip
connections, and ball clamp, to
retain position of tip.
4. Using a pry bar, pry the exhaust
hangers from the factory rubber
isolators.
5. Unbolt the driver side rear mufer
/ tail pipe assembly and remove it.
6. Unbolt the exhaust system from
the catalytic converter assemblies.
11. Slip the U-bolt clamps (F) over
the end of the X-pipe. Then install
the new JBA mufers (B) on to the
end of the X-pipe (A).
12. Align the mufers (B) so they
are at then tighten the U-bolt
clamps (F) over the connection.
13. Install the passenger side tail
pipe with tip (C) hangers into the
rubber isolators. Then slip the other
end onto the mufer (B).
18. Remove factory tips from
original exhaust. Remove original
clamps by carefully rolling off of the
stock ball connector, or you might
have to cut the attaching weld, if it
is too large to break loose.
19. Install stock tips onto the tip
adapters using the original clamp.
Adjust and align. If necessary, tip
adapter can be slid off of tailpipe
slightly to adjust length.
22. Using a soft cloth, remove all
prints from exhaust tip.
23. Check all clamps and connections for proper t and align-
ment. Double check all clamps are
tightened and that all hangers are
secure in rubber grommets. It is
recommended that after installation
of the exhaust system you have all
slip connections tack welded by a
mufer shop.
NOTES:
1. All exhaust systems expand
about 1” rearward when exhaust
temperature rises.
3. Use anti-seize on threads of
clamps.
Other recommended products:
7. Disconnect the ground strap
from the exhaust system and carefully remove the rest of the factory
exhaust system.
8. Slip the supplied Sure-Seal™
clamps (E) over the ends of the
catalytic converter assemblies.
15. Install the driver side tail pipe
with tip (C) hangers into the rubber
isolators. Then slip the other end
onto the mufer (B).
20. Check for adequate clearance
on frame, and body.
Get an extra 20+hp and faster ET’s
with a set of smog legal stainless
steel JBA Cat4ward® headers.
Part No. Applicaton
1964S-1 05-06 5.7L stainless
1964S-1JS 05-06 5.7L silver ceramic
1964S-1JT 05-06 5.7L titanium ceramic
JBA recommends taking the vehicle to a mufer shop and having all slip connections tack welded. 5.6.09
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