PerTronix 40-1535 User Manual

INSTALLATION INSTRUCTIONS

** Installation recommendation: JBA recommends in most case that the vehicle be taken to a reputable exhaust shop for installation.

40-1535

2006 Dodge Ram Quad Cab 5.7L HEMI

Recommended Tools:
pry bar
ratchet

15mm deep socket

channel lock pliers
Anti-seize
spray lubricant or
penetrating oil

Parts List:

A. Intermediate pipe 1
B. Mufer 1
C. Tail pipe 1
D. Turnout w/ tip and hanger 1
E. Mufer hanger clamp 1
F. Exhaust clamp w/ hanger 1

G. 3” exhaust clamp 2

TO START:

1. Remove and inventory JBA exhaust.

2. Disconnect negative battery cable

and allow vehicle exhaust to cool.

3. With the vehicle raised and properly

supported, using the 15mm socket and

ratchet, loosen the clamp, at the rear

of the mufer, that secures the tail
pipe to the mufer.

A

G

8. Using the 15mm socket and ratchet,

loosen the clamp that secures the
mufer assembly to the resonator/in­termediate pipe.

B

E

C

F

13. Insert mufer (B) into intermediate
pipe (A). Place exhaust clamp with
hanger (G) at the front of the mufer.
NOTE: Support the mufer temporarily,
until the mufer hanger clamp is used.

D

G

18. Install turnout w/ tip (D) at the end
of tail pipe (C).

4. Spray lubricant on the exhaust pipe

behind the mufer.

5. Spray lubricant on all factory rubber

isolators.

9. Remove mufer hangers from

rubber isolators.

10. Remove factory mufer assembly.

19. Insert turnout w/ tip and hanger

into rubber isolator at the rear of the
vehicle, near the spare tire.

14. Install tail pipe (C) through the rear

of the vehicle.

20. Position exhaust clamp (H) over
slip connection on turnout w/ tip (D).

15. Insert tail pipe (C) through mufer
hanger clamp (E) and into mufer (B).

21. Align exhaust tip (D) properly and
tighten clamp (G).

22. After installation, it is recommend­ed that all clamps be re-tightened.

23. Tack weld all slip connections in

three spots.

24. Lower the 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 tem-

peratures start to rise.

3) Use Anti-seize on threads of

clamps.

6. Remove the factory tail pipe hanger

from rubber isolator.

7. Remove tail pipe from the rear of
the vehicle.

11. Install mufer hanger clamp (E)

into rubber isolators near the rear of

the factory mufer location.

12. Install intermediate pipe (A) and
secure with exhaust clamp (G).

16. Align tail pipe (C) properly and
tighten mufer hanger clamp (E).

17. Install exhaust clamp (H) loosely
over tail pipe (C). Do not tighten at this

point.

JBA recommends taking the vehicle to a mufer shop and having all slip connections tack welded. 11.15.06