INSTALLATION INSTRUCTIONS
**Installation recommendation:
JBA recommends in most cases that the vehicle be taken to a reputable exhaust shop.
40-2523 Reg Cab / Short Bed
40-2524 Reg Cab / Long Bed
40-2525 Super Cab / Short Bed
40-2526 Super Cab / Long Bed
40-2527 Super Crew
TOOLS RECOMMENDED:
ratchet
socket set
channel lock pliers
rubber mallet
spray lubricant
anti-seize (for stainless)
pry bar
Start:
1. Remove and inventory new
JBA exhaust system.
2. Disconnect negative battery
cable and allow vehicle to cool.
Parts List:
A. Intermediate pipe 1
B. JBA high flow muffler 1
C. Tail pipe with hangers 1
D. Turn out with tip 1
E. 2-1/2" clamp 1
F. 3" Clamp 2
G. 3" Clamp with hanger 1
8. Slide the new JBA tail pipe
with hangers (C) over the rear
axle.
2004 Ford F-150 5.4L 3v V8
F
B
F
C
"A" length:
2523 = 22-1/4"
D
30-2526 shown
12. Slip the JBA muffler (B) onto
the front of the tail pipe (C) with
the "inlet" sticker towards the
front of the vehicle.
2524 = 39-1/4"
2525 = 22-1/4"
2526 = 51-1/4"
2527 = 33-3/4"
A
E
18. Check the alignment of the
installed system then tight the
clamps on the intermediate pipe
(A) and muffler (B).
G
3. Loosen the clamp connecting
the factory intermediate pipe to
the head pipe assembly.
4. Then slide the clamp back.
5. Spray the rubber isolator
hangers with WD40 or similar
lubricant.
6. Using a pry bar, push the
exhaust system back until the
exhaust hangers drop free from
the rubber isolators. Caution:
Be careful not to let the exhaust
system fall on you or damage
the rear fender.
9. Insert the rear hanger on tail
pipe (C) into the rear rubber
isolator. Spray with lube if needed.
10. Slip the front hanger on tail
pipe (C) into the rear muffler
hanger isolator. Position pipe so
there is approx. 3/4" gap between
hanger and heat shield.
Note: On stainless steel system
apply anti-sieze to the threads of
the supplied stainless steel
clamps before installing them.
13. Insert the 3" clamp with
hanger (G) into the front rubber
isolator hanger.
14. Snug the 3" clamp with
hanger (G) on the front of the
JBA muffler (B).
15. Slip the supplied 2-1/2"
clamp (E) on to the factory head
pipe assembly.
19. Slip the 3" clamp (F) over
the rear of the tail pipe (C)
20. Slide the turn out with tip (D)
on to the tail pipe (C) and align
tip with approximately 1-1/2"
clearance on rear fender.
21. Align the turn out (D) for
clearance around spare tire and
rear axle.
22. Check for adequate
clearance for the chrome tip
from paint and body. With the
turn out (D) properly aligned,
secure it in place by tightening
the 3" clamp (F).
16. Install the supplied
intermediate pipe (A) onto the
factory head pipe. Make sure to
line up the keyway.
7. Carefully lower the exhaust
system and remove it from the
vehicle.
We recommend taking the vehicle to a muffler shop and having all slip connections tack welded.
11. Slip a 3" clamp (F) on the
front of the tail pipe (C).
17. Insert the intermediate pipe
(A) into the JBA muffler (B).
23. Using a soft cloth, remove
all prints from the exhaust tip.
24. Check all clamps and
connections for proper fit and
alignment. Double check all
clamps are tightened and that all
hangers are secure in rubber
grommets. It is recommended
that after installation of this
system you have all slip
connections tack welded by a
muffler shop.
NOTES:
1.) It may be necessary 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
stainless steel clamps.
4.16.07vt
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