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40-1504
User Manual
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PerTronix 40-1504 User Manual

INSTALLATION INSTRUCTIONS
1994-97 Dodge Ram 1500/2500
TOOLS RECOMMENDED:
TO ST ART :
9/16 deep socket ratchet 10mm wrench 15mm deep socket prybar rubber mallet spray lubricant or penetrating oil anti-seize reciprocating saw or hack saw pair of channel lock pliers
2. Disconnect negative battery cable and allow vehicle exhaust to cool.
3. With vehicle raised and properly sup­ported, using a reciprocating saw or hack saw, cut tail pipe approximately 1î behind rear muffler clamp and in front of tail pipe hanger.
4. Spray lubricant on lower holes of front and rear tail pipe hanger rubber grommets.
5. Remove lower bolt from rear tailpipe hanger.
INSTALLATION INSTRUCTIONS
1994-97 Dodge Ram 1500/2500
TOOLS RECOMMENDED:
TO ST ART :
9/16 deep socket ratchet 10mm wrench 15mm deep socket prybar rubber mallet spray lubricant or penetrating oil anti-seize reciprocating saw or hack saw pair of channel lock pliers
2. Disconnect negative battery cable and allow vehicle exhaust to cool.
3. With vehicle raised and properly sup­ported, using a reciprocating saw or hack saw, cut tail pipe approximately 1î behind rear muffler clamp and in front of tail pipe hanger.
4. Spray lubricant on lower holes of front and rear tail pipe hanger rubber grommets.
5. Remove lower bolt from rear tailpipe hanger.
INSTALLATION INSTRUCTIONS
1994-97 Dodge Ram 1500/2500
TOOLS RECOMMENDED:
TO ST ART :
9/16 deep socket ratchet 10mm wrench 15mm deep socket prybar rubber mallet spray lubricant or penetrating oil anti-seize reciprocating saw or hack saw pair of channel lock pliers
2. Disconnect negative battery cable and allow vehicle exhaust to cool.
3. With vehicle raised and properly sup­ported, using a reciprocating saw or hack saw, cut tail pipe approximately 1î behind rear muffler clamp and in front of tail pipe hanger.
4. Spray lubricant on lower holes of front and rear tail pipe hanger rubber grommets.
5. Remove lower bolt from rear tailpipe hanger.
INSTALLATION INSTRUCTIONS
1994-97 Dodge Ram 1500/2500
TOOLS RECOMMENDED:
TO ST ART :
9/16 deep socket ratchet 10mm wrench 15mm deep socket prybar rubber mallet spray lubricant or penetrating oil anti-seize reciprocating saw or hack saw pair of channel lock pliers
2. Disconnect negative battery cable and allow vehicle exhaust to cool.
3. With vehicle raised and properly sup­ported, using a reciprocating saw or hack saw, cut tail pipe approximately 1î behind rear muffler clamp and in front of tail pipe hanger.
4. Spray lubricant on lower holes of front and rear tail pipe hanger rubber grommets.
5. Remove lower bolt from rear tailpipe hanger.
10. Using some form of heat and force, disengage and remove muffler without damaging head pipe.
17. Position 3" clamp (H) over slip joint on turn out (D) and hand tighten. NOTE: use anti-seize on threads.
1. Remove and inventory new JBA exhaust.
11.Align notch with locating pin and install head pipe (A) using the 2-1/2" clamp (E). Tighten completely with 9/16" deep wall socket. NOTE: Use anti-seize on threads.
6. Using a pair of channel lock pliers, remove front tail pipe hanger rod from bottom hole in rubber grommet.
7. Remove tail pipe from rear of vehicle.
13. Using the 3" clamp (F), tighten clamp completely using 9/16" deep wall socket. NOTE: use anti-seize on threads.
18. Check all pipes for proper clearance and tighten the 3" clamp (G) completely at rear of muffler.
19. Check turn out (D) position and tighten clamp (H) completely.
20. After installation, it is recommended that all clamps be retightened and joints tach welded in 3 spots.
21. Using a soft cloth, remove all prints from turnout tip.
22. Lower vehicle and reattach the nega­tive battery cable.
NOTES:
1) It may be necessary to loosen and realign the spare tire for proper clearance.
2) All exhaust systems will expand about 1" rearward when exhaust temperature start to rise.
3) Use Anti-seize on threads of clamps.
14. Install 3" clamp (G) over rear slip on muffler and install tail pipe (C) from rear of vehicle, bracket end first then slip into muffler
15. Install front two hangers on tail pipe (C) into lower holes of rubber grommet.
16. Install 3" clamp (H) over rear of tail pipe (C). Slip turn out (D) over tail pipe (C). Slip hanger rod into lower hole in rubber grommet.
8. Spray penetrating oil on threads of front muffler clamp.
9. Using a 15mm socket, remove front muffler clamp.
10. Using some form of heat and force, disengage and remove muffler without damaging head pipe.
17. Position 3" clamp (H) over slip joint on turn out (D) and hand tighten. NOTE: use anti-seize on threads.
1. Remove and inventory new JBA exhaust.
11.Align notch with locating pin and install head pipe (A) using the 2-1/2" clamp (E). Tighten completely with 9/16" deep wall socket. NOTE: Use anti-seize on threads.
6. Using a pair of channel lock pliers, remove front tail pipe hanger rod from bottom hole in rubber grommet.
7. Remove tail pipe from rear of vehicle.
13. Using the 3" clamp (F), tighten clamp completely using 9/16" deep wall socket. NOTE: use anti-seize on threads.
18. Check all pipes for proper clearance and tighten the 3" clamp (G) completely at rear of muffler.
19. Check turn out (D) position and tighten clamp (H) completely.
20. After installation, it is recommended that all clamps be retightened and joints tach welded in 3 spots.
21. Using a soft cloth, remove all prints from turnout tip.
22. Lower vehicle and reattach the nega­tive battery cable.
NOTES:
1) It may be necessary to loosen and realign the spare tire for proper clearance.
2) All exhaust systems will expand about 1" rearward when exhaust temperature start to rise.
3) Use Anti-seize on threads of clamps.
14. Install 3" clamp (G) over rear slip on muffler and install tail pipe (C) from rear of vehicle, bracket end first then slip into muffler
15. Install front two hangers on tail pipe (C) into lower holes of rubber grommet.
16. Install 3" clamp (H) over rear of tail pipe (C). Slip turn out (D) over tail pipe (C). Slip hanger rod into lower hole in rubber grommet.
8. Spray penetrating oil on threads of front muffler clamp.
9. Using a 15mm socket, remove front muffler clamp.
10. Using some form of heat and force, disengage and remove muffler without damaging head pipe.
17. Position 3" clamp (H) over slip joint on turn out (D) and hand tighten. NOTE: use anti-seize on threads.
1. Remove and inventory new JBA exhaust.
11.Align notch with locating pin and install head pipe (A) using the 2-1/2" clamp (E). Tighten completely with 9/16" deep wall socket. NOTE: Use anti-seize on threads.
6. Using a pair of channel lock pliers, remove front tail pipe hanger rod from bottom hole in rubber grommet.
7. Remove tail pipe from rear of vehicle.
13. Using the 3" clamp (F), tighten clamp completely using 9/16" deep wall socket. NOTE: use anti-seize on threads.
18. Check all pipes for proper clearance and tighten the 3" clamp (G) completely at rear of muffler.
19. Check turn out (D) position and tighten clamp (H) completely.
20. After installation, it is recommended that all clamps be retightened and joints tach welded in 3 spots.
21. Using a soft cloth, remove all prints from turnout tip.
22. Lower vehicle and reattach the nega­tive battery cable.
NOTES:
1) It may be necessary to loosen and realign the spare tire for proper clearance.
2) All exhaust systems will expand about 1" rearward when exhaust temperature start to rise.
3) Use Anti-seize on threads of clamps.
14. Install 3" clamp (G) over rear slip on muffler and install tail pipe (C) from rear of vehicle, bracket end first then slip into muffler
15. Install front two hangers on tail pipe (C) into lower holes of rubber grommet.
16. Install 3" clamp (H) over rear of tail pipe (C). Slip turn out (D) over tail pipe (C). Slip hanger rod into lower hole in rubber grommet.
8. Spray penetrating oil on threads of front muffler clamp.
9. Using a 15mm socket, remove front muffler clamp.
10. Using some form of heat and force, disengage and remove muffler without damaging head pipe.
17. Position 3" clamp (H) over slip joint on turn out (D) and hand tighten. NOTE: use anti-seize on threads.
1. Remove and inventory new JBA exhaust.
11.Align notch with locating pin and install head pipe (A) using the 2-1/2" clamp (E). Tighten completely with 9/16" deep wall socket. NOTE: Use anti-seize on threads.
6. Using a pair of channel lock pliers, remove front tail pipe hanger rod from bottom hole in rubber grommet.
7. Remove tail pipe from rear of vehicle.
13. Using the 3" clamp (F), tighten clamp completely using 9/16" deep wall socket. NOTE: use anti-seize on threads.
18. Check all pipes for proper clearance and tighten the 3" clamp (G) completely at rear of muffler.
19. Check turn out (D) position and tighten clamp (H) completely.
20. After installation, it is recommended that all clamps be retightened and joints tach welded in 3 spots.
21. Using a soft cloth, remove all prints from turnout tip.
22. Lower vehicle and reattach the nega­tive battery cable.
NOTES:
1) It may be necessary to loosen and realign the spare tire for proper clearance.
2) All exhaust systems will expand about 1" rearward when exhaust temperature start to rise.
3) Use Anti-seize on threads of clamps.
14. Install 3" clamp (G) over rear slip on muffler and install tail pipe (C) from rear of vehicle, bracket end first then slip into muffler
15. Install front two hangers on tail pipe (C) into lower holes of rubber grommet.
16. Install 3" clamp (H) over rear of tail pipe (C). Slip turn out (D) over tail pipe (C). Slip hanger rod into lower hole in rubber grommet.
8. Spray penetrating oil on threads of front muffler clamp.
9. Using a 15mm socket, remove front muffler clamp.
12. With JBA logo facing rear of vehicle, install muffler (B) over head pipe (A) mak­ing sure muffler bottoms out on slip joint.
12. With JBA logo facing rear of vehicle, install muffler (B) over head pipe (A) mak­ing sure muffler bottoms out on slip joint.
12. With JBA logo facing rear of vehicle, install muffler (B) over head pipe (A) mak­ing sure muffler bottoms out on slip joint.
12. With JBA logo facing rear of vehicle, install muffler (B) over head pipe (A) mak­ing sure muffler bottoms out on slip joint.
W e recommend taking the truck to a muffler shop and having all slip connections tack welded.
Part s List
A. Head pipe 1 B. Muffler, 24" 1 C. Tail pipe 1 D. Turn out 1 E. 2-1/2" clamp 1 F. 3" clamp 1 G. 3" clamp 1 H. 3" clamp 1 *I. Rear turnout hanger assembly 1
**Installation recommendation:
JBA recommends in most cases that the vehicle be taken to a reputable exhaust shop.
17038 6-21-02
W e recommend taking the truck to a muffler shop and having all slip connections tack welded.
Part s List
A. Head pipe 1 B. Muffler, 24" 1 C. Tail pipe 1 D. Turn out 1 E. 2-1/2" clamp 1 F. 3" clamp 1 G. 3" clamp 1 H. 3" clamp 1 *I. Rear turnout hanger assembly 1
**Installation recommendation:
JBA recommends in most cases that the vehicle be taken to a reputable exhaust shop.
17038 6-21-02
W e recommend taking the truck to a muffler shop and having all slip connections tack welded.
Part s List
A. Head pipe 1 B. Muffler, 24" 1 C. Tail pipe 1 D. Turn out 1 E. 2-1/2" clamp 1 F. 3" clamp 1 G. 3" clamp 1 H. 3" clamp 1 *I. Rear turnout hanger assembly 1
**Installation recommendation:
JBA recommends in most cases that the vehicle be taken to a reputable exhaust shop.
17038 6-21-02
W e recommend taking the truck to a muffler shop and having all slip connections tack welded.
Part s List
A. Head pipe 1 B. Muffler, 24" 1 C. Tail pipe 1 D. Turn out 1 E. 2-1/2" clamp 1 F. 3" clamp 1 G. 3" clamp 1 H. 3" clamp 1 *I. Rear turnout hanger assembly 1
**Installation recommendation:
JBA recommends in most cases that the vehicle be taken to a reputable exhaust shop.
17038 6-21-02
H
D
I
B
G
F
E
A
C
* On some model years, it may be necessary to bolt rear hanger assembly (I) to hole in frame rail to mount turn out (D).
H
D
I
B
G
F
E
A
C
* On some model years, it may be necessary to bolt rear hanger assembly (I) to hole in frame rail to mount turn out (D).
H
D
I
B
G
F
E
A
C
* On some model years, it may be necessary to bolt rear hanger assembly (I) to hole in frame rail to mount turn out (D).
H
D
I
B
G
F
E
A
C
* On some model years, it may be necessary to bolt rear hanger assembly (I) to hole in frame rail to mount turn out (D).
40-1504
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