PerTronix 40-2530 User Manual

* Installation Recommendation: JBA recommends in most cases that the vehicle be taken to a reputable exhaust shop.

40-2530

2002 Ford Explorer

4.6 / 4.0L 2/4wd

RECOMMENDED TOOLS:

15mm socket
ratchet
channel lock pliers
9/16 socket
hammer
prybar
spry lubricant of penetrating oil

TO START:

1. Remove and inventory JBA exhaust.

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

INSTALLATION INSTRUCTIONS

PARTS LIST:

A. Intermediate pipe 1
B. Muffler 1
C. Over axle pipe 1
D. Tail pipe 1
E. Preformed clamp 1
F. Front muffler clamp 1
G. Rear muffler clamp

D.

B.

C.

E.

G.

1

A.

F.

3. With the vehicle raised and properly
supported, use a 15mm socket to loosen
the clamp on the tailpipe above the
axle shaft.

7. Using a 15mm socket, remove the
fasteners that attach the exhaust system
to the catalytic converter. Save the
fasteners, they will be reused.

8. Remove factory exhaust system from
hangers.

12. Install muffler (B) with offset towards
the rear, outside of the truck.

13. Align the muffler (B) and install and
tighten front muffler clamp (F).

17. Install tail pipe (D), rotate into position.
Slip onto axle pipe.

18. Insert tail pipe hanger rod into
factory isolator.

4. Remove the tailpipe hanger form the
rubber isolator.

5. The tail pipe attaches by a twist-loc set
up. Rotate the tailpipe counter clock wise
and pull apart.

9. Remove factory exhaust system.

10. Install new intermediate pipe (A).

14. Slide rear muffler clamp (G) over
muffler outlet. Install over axle pipe (C)
with hanger in front of axle.

15. Insert over axle pipe (C) into muffler (B).

19 . With the tail pipe (D) and axle pipe (C)
aligned, slip the preformed clamp (E)
onto the axle pipe (D) with the larger
section to the rear of the vehicle.
Tighten preformed clamp (E) and clamp
at the rear of the muffler (G). Tack weld
the muffler.

20. After installation, it is recommended
that all clamps be retightened.

21. Tack weld all slip connections in
three spots.

22. Lower the vehicle and reattach the
negative battery cable.

NOTES:

6. Remove tail pipe assembly from rear
of vehicle.

11. Attach new intermediate pipe (A) to
catalytic converter by using the original
fasteners.

1) All exhaust systems will expand
roughly 1" rearward when exhaust
temperatures start to rise.

2) Use Anti-seize on threads of clamps.

16. Insert forward over axle pipe hanger
rod into factory isolator.