JBA 40-9010 User Manual

INSTALLATION INSTRUCTIONS

**Installation recommendation:

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

40-9010

Toyota 4Runner 96-98 2.7L, 3.4L

2/4 WD

TOOLS RECOMMENDED:

Parts List

3/8" drive ratchet

A. Head pipe with hanger 1

9/16" deep wall socket

B. Muffler 1

1/2" deep wall socket

C. Tail pipe with tip 1

12mm deep wall socket

D. 8mm nuts 2

14mm deep wall socket

E. 2-1/2" clamp 1

pair of channel lock pliers

F. 2-1/2" rear muffler clamp/hanger 1 reciprocating saw or hack saw rubber mallet spray lubricant or penetrating oil

G. Block off plate (not shown)

H. Gasket (not shown)

1 1

anti-seize

TO START:

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

3. With vehicle raised and properly supported, using a 14mm socket remove two flange bolts on tail pipe at rear of muffler.

4. Spray lubricant on rear tail pipe hanger rod, and remove from rubber grommet using channel lock pliers.

1. Remove and inventory new JBA exhaust.

5. Remove tail pipe from rear of vehicle.

12. Install oxygen sensor & gasket on JBA head pipe (A) using two 8mm nut's (D) and tighten using 1/2'' socket. NOTE: USE ANTI SEIZE ON THREADS.

13. Install rear muffler clamp/hanger (F) with ends of hanger rods forward.

14. Install muffler (B) with off set end toward rear and inward. Slip on 2''.

20. Tighten rear muffler clamp/hanger (F) completely using a 9/16'' socket. NOTE: USE ANTI SEIZE ON THREADS. See Notes #1

20.

Check exhaust for proper clearance and location of tip. Retighten all clamps and tack weld all slip joints in three spots.

NOTES:

1) If anti seize is not used on threads of clamps before tightening, the nuts will gall and clamp will break.

9. Remove muffler assembly, taking care not to damage flange gasket , it will be reused.

10. Remove gasket from stock head pipe flange, and install it on th JBA head pipe.

11. Install JBA head pipe (A) using stock bolts and tighten using 14mm socket.

8. Spray lubricant on rear muffler hanger rods and remove from lower holes using channel lock pliers.

6. Remove oxygen sensor using a 12mm socket,taking care not to damage gasket as it will be reused.

7. With muffler properly supported, remove two flange bolts at front of muffler using a 14mm socket. Save bolts they will be reused.

15. Position rear clamp/hanger (F) over end of muffler and hand tighten only at this time. NOTE: USE ANTI SEIZE ON THREADS. See notes #1

16. Install front muffler clamp (E) and position over slip joint. Align muffler and tighten clamp (E) completely using a 9/16'' socket. NOTE: USE ANTI SEIZE ON THREADS. See Notes #1

17. Install tail pipe (C) from rear of vehicle and slip into rear of muffler 2''.

18. Install rear tail pipe hanger rod into lower hole in rubber grommet.

19. Rotate tail pipe (C) for proper clearance on rear body panel and rear cross member. Clearance on cross member should be 1'' to 1-1/2''.

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

2.7.06

21. Lower vehicle and reattach negative battery cable.