PerTronix 40-15201 User Manual
INST ALLA TION INSTR UCTIONS
40-1520
2002 Dodge Ram quad cab/std. bed 4.7/5.9L V-8
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 1" 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.
INST ALLA TION INSTR UCTIONS
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 t
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.
INST ALLA TION INSTR UCTIONS
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 t
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.
INSTALLATION INSTRUCTIONS
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 t
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. Using a pair of channel lock pliers,
remove hanger rods from bottom holes of
two rear tail pipe rubber grommets.
8. Using some form of heat and force,
disengage and remove muffler without
damaging head pipe.
15. Install turn out clamp (H)
over end of tail pipe (C) and into rubber
grommet.
1. Remove and inventory new JBA
exhaust.
9. 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.
11. Using the 3" clamp (F), tighten clamp
completely using 9/16" deep wall socket.
20. After installation, it is recommended
that all clamps be retightened and joints
tack 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.
12. Install tail pipe (C) from rear of vehicle with double hanger towards muffler.
13. Install front two hangers on tail pipe
(C) into lower holes of rubber grommet.
14. Install rear tail pipe hanger into rubber
grommet. Align tail pipe and tighten 3"
clamp (G) completely. Note: Use antiseize on threads.
5. Using a pair of channel lock pliers,
remove hanger rods from bottom holes of
two rear tail pipe rubber grommets.
8. Using some form of heat and force,
disengage and remove muffler without
damaging head pipe.
15. Inst
over end of tail pipe (C) and into rubber
grommet.
exhaust.
9. Align notch with locating pin and install
T
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.
20. After installation, it is recommended
that all clamps be retightened and joints
tack 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
start to rise.
3) Use Anti-seize on threads of clamps.
12. Install tail pipe (C) from rear of vehicle with double hanger towards muffler.
13. Install front two hangers on tail pipe
(C) into lower holes of rubber grommet.
14. Install rear tail pipe hanger into rubber
grommet. Align t
clamp (G) completely. Note: Use antiseize on threads.
5. Using a pair of channel lock pliers,
remove hanger rods from bottom holes of
two rear tail pipe rubber grommets.
8. Using some form of heat and force,
disengage and remove muffler without
damaging head pipe.
15. Inst
over end of tail pipe (C) and into rubber
grommet.
exhaust.
9. Align notch with locating pin and install
T
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.
20. After installation, it is recommended
that all clamps be retightened and joints
tack 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
start to rise.
3) Use Anti-seize on threads of clamps.
12. Install tail pipe (C) from rear of vehicle with double hanger towards muffler.
13. Install front two hangers on tail pipe
(C) into lower holes of rubber grommet.
14. Install rear tail pipe hanger into rubber
grommet. Align t
clamp (G) completely. Note: Use antiseize on threads.
5. Using a pair of channel lock pliers,
remove hanger rods from bottom holes of
two rear tail pipe rubber grommets.
8. Using some form of heat and force,
disengage and remove muffler without
damaging head pipe.
15. Inst
over end of tail pipe (C) and into rubber
grommet.
exhaust.
9. Align notch with locating pin and install
T
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.
20. After installation, it is recommended
that all clamps be retightened and joints
tack 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
start to rise.
3) Use Anti-seize on threads of clamps.
12. Install tail pipe (C) from rear of vehicle with double hanger towards muffler.
13. Install front two hangers on tail pipe
(C) into lower holes of rubber grommet.
14. Install rear tail pipe hanger into rubber
grommet. Align t
clamp (G) completely. Note: Use antiseize on threads.
10. With JBA logo facing rear of vehicle,
install muffler (B) over head pipe (A) making sure muffler bottoms out on slip joint.
10. With JBA logo facing rear of vehicle,
install muffler (B) over head pipe (A) making sure muffler bottoms out on slip joint.
10. With JBA logo facing rear of vehicle,
install muffler (B) over head pipe (A) making sure muffler bottoms out on slip joint.
10. With JBA logo facing rear of vehicle,
install muffler (B) over head pipe (A) making sure muffler bottoms out on slip joint.
18. Install turn out (D) to end of tail pipe
(C) rotate to desired position approx. 1"
from body.
18. Install turn out (D) to end of tail pipe
(C) rot
from body.
18. Install turn out (D) to end of tail pipe
(C) rot
from body.
18. Install turn out (D) to end of tail pipe
(C) rot
from body.
19. Tighten clamp (H) completely
using 9/16" deep wall socket.
Note: Use anti-seize on threads.
19. T
Note: Use anti-seize on threads.
19. T
Note: Use anti-seize on threads.
19. T
Note: Use anti-seize on threads.
W e recommend t aking 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 hanger 1
G. 3" clamp hanger 1
H. 3" clamp 1
**Installation recommendation:
JBA recommends in most cases that the vehicle be taken to a reputable exhaust shop.
17039a
7-3-02
W e recommend t
Part s List
A. Head pipe 1
B. Muffler 1
C. Tail pipe 1
D. Turn out 1
E. 1
F. 1
G. 1
H. 1
**Installation recommendation:
17039a
W e recommend t
Part s List
A. Head pipe 1
B. Muffler 1
C. Tail pipe 1
D. Turn out 1
E. 1
F. 1
G. 1
H. 1
**Installation recommendation:
17039a
We
Part s List
A. Head pipe 1
B. Muffler 1
C. Tail pipe 1
D. Turn out 1
E. 1
F. 1
G. 1
H. 1
**Installation recommendation:
17039a
H
D
G
E
A
G
E
A
G
E
A
B
G
F
E
A (For 1520)
C
40-1521
2002 Dodge Ram std. cab/short bed 4.7/5.9L V-8
A (For 1521)
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