PerTronix 40-2540 User Manual

INSTALLATION INSTRUCTIONS

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

40-2540

1998-2004 Ford Ranger

2.5L / 3.0L / 4.0L 2/4wd
Standard cab / short bed

RECOMMENDED TOOLS:

pry bar
ratchet
15 m m deep socket
pair of channel lock pliers
anti-seize
spra y lubricant or penetrating oil

TO S TAR T:

1. R emove and inventory JBA exhaust.

2. Disconnect negative battery ca ble a nd a llow
vehicle exha ust to cool.

PARTS LIST:

A. Interm ediate pipe 1
B. Muffler 1
C. Tail pipe 1
D. Rear m uffler clamp 1
E. Front muffler clamp 1

7. Using origina l fasteners, connect intermediate
pipe (A) to the factory catalytic converter pipe.

E.

A.

B.

11 . Attach clamp (E) to the front of the muffler (B).

D.

C.

16 . Align tail pipe (C). tighten cla mp (D).

3. With the vehicle rais ed and properly
supported, use a 15mm socket to remove the
bolts that attach the exha ust system to the
Cata lytic converter.

4. Using a pry bar or a pair of channel lock pliers,
remove hangers from rubber isola tors at the top
of the muffle r.

8. Tighten the fasteners.

9. Slip muffler (B ) onto intermedia te pipe (A).

12. Install tailpipe (C).

13 . I nsert tailpipe (C) into m uffle r (B).

17 . After installation, it is recomme nded
that all clamps be re- tig htened.

18. Tack weld all slip connections in three spots.

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

NOTES:

1) It ma y be necess ary to loosen a nd realign the
sparetireforproperclearance.

2) All exhaust systems will expand about 1"
rearward when exhaust temperatures s tart to rise

3)UseAnti-seizeonthreadsofclamps.

5. Using the channel lock pliers, remove the
tail pipe hanger f rom the rubber isolator.

6. R emove the original exhaust system from
the vehicle.

14 . Install ta il pipe ha nger into factory rubber
isolator.

10 . Insert hanger rods on the muffler into the
factory rubber isolators.

15. Install clamp (D) onto rear of muffler (#).