PerTronix 40-2532 User Manual

INSTALLATION INSTRUCTIONS

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

40-2532

1997-2001 Ford Explorer

E.

4.0L (dual inlet muffler) 4 door 2/4wd

RECOMMENDED TOOLS:

Reciprocating saw
15mm deep socket
ratchet
pair of channel lock pliers
spray lubricant or penetrating oil
anti-seize

TO START:

1. Remove and inventory JBA exhaust.

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

PARTS LIST:

A. Intermediate pipe 1
B. Muffler 1
C. Tail pipe 1
D. Rear muffler hanger clamp 1
E. 2.5" Exhaust clamp 2
F. Turnout with tip 1
G. 2.25" Exhaust clamp 1

7. Remove tail pipe hanger from rubber
isolator.Remove tail pipe.

G

E.

A.

11.Tighten new intermediate pipe (A).
NOTE: do not over tighten fasteners.

D.

C.

B.

15. Reconnect sway bar end link.

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

F.

3.With the vehicle raised and properly
supported, using the ratchet and the
15mm socket, remove the nut that
attaches the sway bar to the sway bar
end link on the right side of the vehicle.

4. Disconnect sway bar.

8. Using the 15mm socket, remove
fasteners attaching intermediate
pipe to catalytic converter.

17.Tack weld all slip connections in
three spots.

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

12. Insert muffler (B). into intermediate
pipe (A). Install front muffler clamp (E).

NOTES:

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

2) Use Anti-seize on threads of clamps.

5. Move sway bar end link forward
and out of the way.

6. Using the reciprocating saw cut
the tail pipe at the rear of the muffler.

9. Remove muffler hangers from rubber
isolators. Remove muffler.

10. Using the factory fasteners and
the supplied 2.25" clamp (G), Install
new intermediate pipe (A).

13. Install rear muffler hanger clamp (D).

14. Install tail pipe (C). Insert tail pipe (C)
into muffler (B). Slip turn out with Tip (F)
onto endoftailpipe(C)andsecure
with 2.5" clamp (E). Insert turn out
hanger into factory rubber isolator.
Align the tail pipe properly and tighten
hanger clamp (D) at the rear of muffler.

04.16.07