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40-3003
User Manual
1 pgs128.39 Kb0

JBA 40-3003 User Manual

INSTALLATION INSTRUCTIONSINSTALLATION INSTRUCTIONSINSTALLATION INSTRUCTIONSINSTALLATION 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.JBA recommends in most cases that the vehicle be taken to a reputable exhaust shop.JBA recommends in most cases that the vehicle be taken to a reputable exhaust shop.JBA recommends in most cases that the vehicle be taken to a reputable exhaust shop.
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G
G
40-3003
GM PickupGM PickupGM PickupGM Pickup 96-98 V8-5.7L96-98 V8-5.7L96-98 V8-5.7L96-98 V8-5.7L SSSSttttd. cab, Sd. cab, Sd. cab, Sd. cab, Sttttd. bedd. bedd. bedd. bed
G
F
F
F
F
E
E
E
E
TTTTOOLS RECOMMENDED:OOLS RECOMMENDED:OOLS RECOMMENDED:OOLS RECOMMENDED:
reciprocating saw or hack sawreciprocating saw or hack sawreciprocating saw or hack sawreciprocating saw or hack saw prybarprybarprybarprybar rubber malletrubber malletrubber malletrubber mallet ratchetratchetratchetratchet 15mm deep socket15mm deep socket15mm deep socket15mm deep socket 9/16 box wrench or socket9/16 box wrench or socket9/16 box wrench or socket9/16 box wrench or socket 7/8" open end wrench7/8" open end wrench7/8" open end wrench7/8" open end wrench ppppair of channel lock pliersair of channel lock pliersair of channel lock pliersair of channel lock pliers 13mm socket13mm socket13mm socket13mm socket anti-seizeanti-seizeanti-seizeanti-seize impimpimpimpact wrenchact wrenchact wrenchact wrench spray lubricant or penetrating oilspray lubricant or penetrating oilspray lubricant or penetrating oilspray lubricant or penetrating oil
PartPartPartPart s Lists Lists Lists List
FFFF.... Rear mufRear mufRear mufRear muffler clamp/hanger 3"fler clamp/hanger 3"fler clamp/hanger 3"fler clamp/hanger 3" 1111
GGGG.... TTTTurn out clamp 3"urn out clamp 3"urn out clamp 3"urn out clamp 3" 1111
TTTT OOOO STSTSTST ARTARTARTART ::::
1. Remove and inventory new JBA1. Remove and inventory new JBA1. Remove and inventory new JBA1. Remove and inventory new JBA exhaust.exhaust.exhaust.exhaust.
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 the t, cut the t, cut the t, cut the tail pipe approximately 3"ail pipe approximately 3"ail pipe approximately 3"ail pipe approximately 3"
behind rear mufbehind rear mufbehind rear mufbehind rear muffler hangerfler hangerfler hangerfler hanger....
D
D
D
D
CCCC
9. Remove three nut9. Remove three nut9. Remove three nut9. Remove three nuts on three bolt flanges on three bolt flanges on three bolt flanges on three bolt flange using 15mm socket.using 15mm socket.using 15mm socket.using 15mm socket. YYYYou may want to useou may want to useou may want to useou may want to use some penetrating oil.some penetrating oil.some penetrating oil.some penetrating oil.
10. Using a p10. Using a p10. Using a p10. Using a pair of channel lock pliers,air of channel lock pliers,air of channel lock pliers,air of channel lock pliers, remove front and rear mufremove front and rear mufremove front and rear mufremove front and rear muffler hanger rodsfler hanger rodsfler hanger rodsfler hanger rods from bottom holes of grommetfrom bottom holes of grommetfrom bottom holes of grommetfrom bottom holes of grommets.s.s.s. Note:Note:Note:Note: support mufsupport mufsupport mufsupport muffler before stfler before stfler before stfler before starting.arting.arting.arting.
15. With muf15. With muf15. With muf15. With muffler (B) in place, instfler (B) in place, instfler (B) in place, instfler (B) in place, install muf-all muf-all muf-all muf­fler clamp (E) on slip fit joint. Position 1/4"fler clamp (E) on slip fit joint. Position 1/4"fler clamp (E) on slip fit joint. Position 1/4"fler clamp (E) on slip fit joint. Position 1/4" from lip.from lip.from lip.from lip. TTTTighten clamp completely withighten clamp completely withighten clamp completely withighten clamp completely with 9/16" deep wall socket. NOTE: Use some9/16" deep wall socket. NOTE: Use some9/16" deep wall socket. NOTE: Use some9/16" deep wall socket. NOTE: Use some anti-seize on all threads.anti-seize on all threads.anti-seize on all threads.anti-seize on all threads.
16. Inst16. Inst16. Inst16. Install rear mufall rear mufall rear mufall rear muffler clamp/hanger (F)fler clamp/hanger (F)fler clamp/hanger (F)fler clamp/hanger (F) over slip joint on rear of mufover slip joint on rear of mufover slip joint on rear of mufover slip joint on rear of mufflerflerflerfler. Do not. Do not. Do not. Do not tighten at this time.tighten at this time.tighten at this time.tighten at this time.
A
A
A
B
B
B
B
22. Position rear muf22. Position rear muf22. Position rear muf22. Position rear muffler clamp/hanger (F)fler clamp/hanger (F)fler clamp/hanger (F)fler clamp/hanger (F) 1/4" from lip on slip joint and tighten com-1/4" from lip on slip joint and tighten com-1/4" from lip on slip joint and tighten com-1/4" from lip on slip joint and tighten com­pletely with 9/16" deep wall socket. Note:pletely with 9/16" deep wall socket. Note:pletely with 9/16" deep wall socket. Note:pletely with 9/16" deep wall socket. Note: Use anti-seize on threads.Use anti-seize on threads.Use anti-seize on threads.Use anti-seize on threads.
A
4. S4. S4. S4. Spray lubricant on rear tpray lubricant on rear tpray lubricant on rear tpray lubricant on rear tail pipe hangerail pipe hangerail pipe hangerail pipe hanger 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 rod from bottom hole ofremove hanger rod from bottom hole ofremove hanger rod from bottom hole ofremove hanger rod from bottom hole of grommet.grommet.grommet.grommet.
6. Remove t6. Remove t6. Remove t6. Remove tail pipe assembly from theail pipe assembly from theail pipe assembly from theail pipe assembly from the rear of vehicle.rear of vehicle.rear of vehicle.rear of vehicle.
7. S7. S7. S7. Spray lubricant on front and rear mufpray lubricant on front and rear mufpray lubricant on front and rear mufpray lubricant on front and rear mufflerflerflerfler hanger grommethanger grommethanger grommethanger grommets.s.s.s.
11111. Remove muf1. Remove muf1. Remove muf1. Remove muffler assembly pullingfler assembly pullingfler assembly pullingfler assembly pulling towards rear of vehicle. Note: use care nottowards rear of vehicle. Note: use care nottowards rear of vehicle. Note: use care nottowards rear of vehicle. Note: use care not to damage gasket on three bolt flange.to damage gasket on three bolt flange.to damage gasket on three bolt flange.to damage gasket on three bolt flange.
12. Inst12. Inst12. Inst12. Install head pipe (A) with three boltall head pipe (A) with three boltall head pipe (A) with three boltall head pipe (A) with three bolt flange. Instflange. Instflange. Instflange. Install hanger through lower holeall hanger through lower holeall hanger through lower holeall hanger through lower hole in rubber grommet.in rubber grommet.in rubber grommet.in rubber grommet. TTTTighten three nutighten three nutighten three nutighten three nutssss using 15mm socket.using 15mm socket.using 15mm socket.using 15mm socket. Note:Note:Note:Note: we recom-we recom-we recom-we recom- mend using anti-seize on threads.mend using anti-seize on threads.mend using anti-seize on threads.mend using anti-seize on threads.
13. Inst13. Inst13. Inst13. Install oxygen sensor using 7/8"all oxygen sensor using 7/8"all oxygen sensor using 7/8"all oxygen sensor using 7/8" wrench.wrench.wrench.wrench.
17. Slip clamp/hanger (F) into lower hole17. Slip clamp/hanger (F) into lower hole17. Slip clamp/hanger (F) into lower hole17. Slip clamp/hanger (F) into lower hole on rubber grommet.on rubber grommet.on rubber grommet.on rubber grommet.
18. Inst18. Inst18. Inst18. Install tall tall tall tail pipe (C) from rear into slipail pipe (C) from rear into slipail pipe (C) from rear into slipail pipe (C) from rear into slip joint on mufjoint on mufjoint on mufjoint on muffler (B). Slip approx. 2".fler (B). Slip approx. 2".fler (B). Slip approx. 2".fler (B). Slip approx. 2".
19. Slip rear t19. Slip rear t19. Slip rear t19. Slip rear tail pipe (C) hanger intoail pipe (C) hanger intoail pipe (C) hanger intoail pipe (C) hanger into lower hole in rubber grommet.lower hole in rubber grommet.lower hole in rubber grommet.lower hole in rubber grommet.
20. Position t20. Position t20. Position t20. Position tail pipe (C) so hanger is notail pipe (C) so hanger is notail pipe (C) so hanger is notail pipe (C) so hanger is not cocked at an angle, and rubber grommetcocked at an angle, and rubber grommetcocked at an angle, and rubber grommetcocked at an angle, and rubber grommet is angled forward.is angled forward.is angled forward.is angled forward.
21. Inspect clearance around rear-end21. Inspect clearance around rear-end21. Inspect clearance around rear-end21. Inspect clearance around rear-end shock and spshock and spshock and spshock and spare tire.are tire.are tire.are tire.
23. Slip turn out clamp (G) onto t23. Slip turn out clamp (G) onto t23. Slip turn out clamp (G) onto t23. Slip turn out clamp (G) onto tail pipe.ail pipe.ail pipe.ail pipe. Slip turn out (D) on tSlip turn out (D) on tSlip turn out (D) on tSlip turn out (D) on tail pipe (C) approx.ail pipe (C) approx.ail pipe (C) approx.ail pipe (C) approx. 1-1/2î. Rot1-1/2î. Rot1-1/2î. Rot1-1/2î. Rotate tip to desired position leav-ate tip to desired position leav-ate tip to desired position leav-ate tip to desired position leav­ing clearance from bodying clearance from bodying clearance from bodying clearance from body. Position clamp. Position clamp. Position clamp. Position clamp (G) with threads in an upward position.(G) with threads in an upward position.(G) with threads in an upward position.(G) with threads in an upward position. TTTTighten completely with 9/16" deep wallighten completely with 9/16" deep wallighten completely with 9/16" deep wallighten completely with 9/16" deep wall socket. Note: use anti-seize on threads.socket. Note: use anti-seize on threads.socket. Note: use anti-seize on threads.socket. Note: use anti-seize on threads.
24. Using a sof24. Using a sof24. Using a sof24. 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.
25. Lower vehicle and reatt25. Lower vehicle and reatt25. Lower vehicle and reatt25. 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 1î rearward when exhaust temperature1î rearward when exhaust temperature1î rearward when exhaust temperature1î rearward when exhaust temperature 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 D,s D,s D,s D,
E and FE and FE and FE and F....
14. Slip muf14. Slip muf14. Slip muf14. Slip muffler (B) on head pipe approxi-fler (B) on head pipe approxi-fler (B) on head pipe approxi-fler (B) on head pipe approxi­mately 2". Note:mately 2". Note:mately 2". Note:mately 2". Note: YYYYou may have to tou may have to tou may have to tou may have to tap it inap it inap it inap it in with a rubber mallet. Make sure JBA logowith a rubber mallet. Make sure JBA logowith a rubber mallet. Make sure JBA logowith a rubber mallet. Make sure JBA logo
8. Remove oxygen sensor with 7/8" open8. Remove oxygen sensor with 7/8" open8. Remove oxygen sensor with 7/8" open8. Remove oxygen sensor with 7/8" open end wrench.end wrench.end wrench.end wrench.
WWWWeeee recommend taking the truck to a muffler shop and having all slip connections tack welded.recommend taking the truck to a muffler shop and having all slip connections tack welded.recommend taking the truck to a muffler shop and having all slip connections tack welded.recommend taking the truck to a muffler shop and having all slip connections tack welded.
is to the rearis to the rearis to the rearis to the rear....
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4/17/07
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