JBA 40-3027 User Manual

INSTALLATION INSTRUCTIONSINSTALLATION INSTRUCTIONSINSTALLATION INSTRUCTIONSINSTALLATION INSTRUCTIONS

**Installation rec ommendation:

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

40-3027

02-04 Chevrolet Trailblazer
I-6 4.2L 2/4 WD

TTTTOOLS R E C OMMENDE D:

ratchet
9/16" deep socket
15mm deep socket
pair of channel lock pliers
reciprocating saw or hack saw
rubber mallet
spray lubricant or penetrating oil
anti-seize
prybar

Start:

1. Remove and inventory new
JBA exhaust system.

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

Parts List

A. Head pipe with hanger 1
B. Muffler 22" 1
C. Tail pipe with hanger 1
D. Tip with resonator 1
E. Front muf fler clamp 3" 2
F... Rear muffler clamp/hanger 3" 1
G. 10mm nut 2
H. 10mm flat washer 2
I. 10mm lock washer 2

A

7. Install the new JBA muffler
(B) onto the intermediate pipe
(A) and then position the 3"
clamp over slip connection.

E

B

E

11. Insert the tail pipe hanger
into the rubber grommet behind
the muffler.

F

C

D

3. With vehicle raised and
properly supported, using a
reciprocating saw or hack saw,
cut the tail pipe approximately 3"

.

behind the muffler.

4. Remove the nuts attaching
the intermediate pipe to the
catalytic converter assembly
using a 9/16" deep socket.

8. Spray lubricant on the rear
hanger grommet. Remove the
rear hanger from the grommet
using a pair of channel lock
pliers.

12. Slip the tailpipe (C) together
with the muffler (B) outlet. Attach
the 3" clamp over the
connection.

13. Slip 3" clamp with hanger
(X) over the end of tail pipe (C).
Install hanger into rear hanger
grommet as shown.

16. Check for adequate
clearance from rear bumper and
tighten 3" clamp with hanger.

17. Using a soft cloth, remove
all prints from exhaust tip.

18. Check all clamps and
connections for proper fit and
alignment. Double check all
clamps are tightened.

18. Check all clamps and
connections for proper fit and
alignment. Double check all
clamps are tightened.

NOTES:

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

2.) All exhaust systems expand
about 1" rearward when exhaust
temperature rises.

3. Use anti-seize on threads of
clamps.

5. Spray lubricant on the
intermediate pipe hanger
grommet and then remove the
pipe.

6. Install the new intermediate
pipe (A) into the hanger
grommet.

7. Using a 9/16" deep socket,
attach the intermediate pipe to
the catalytic converter assembly.

9. Remove the tail pipe and rear
muffler assembly from the rear
of the vehicle.

10. Install the new tail pipe (C)
over the rear axle with the
hanger closest to the muffler.

14. Install the tip with resonator
(D) onto the end of the the tail
pipe (C).

15. Align the tip and resonator
and slide the 3" clamp with
hanger over the slip connection.

We recommend taking the truck to a muffler shop and having all slip connections tack welded.

4.20.07