PerTronix 40-3007 User Manual

INSTALLATION INSTRUCTIONS

INSTALLATION INSTRUCTIONS

INSTALLATION INSTRUCTIONS

INSTALLATION INSTRUCTIONS

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

40-3007

GM Silverado / Sierra
2002 4.3/4.8/5.3L
Regular cab / short bed 2/4 wd

T OOLS RECOMMENDED:

T

T

T

ratchet
9/16" deep socket
15mm deep socket
pair of channel lock pliers
reciprocating saw or hack saw
rubber mallet
spray lubricant or penetrating oil
anti-seize
prybar

TO ST ART :

TO ST ART :

TO ST ART :

TO ST ART :

1. Remove and inventory new Evol™

1. Remove and inventory new Evol™

1. Remove and inventory new Evol™

1. Remove and inventory new Evol™
exhaust.

exhaust.

exhaust.

exhaust.

2. Disconnect negative battery cable and

2. Disconnect negative battery cable and

2. Disconnect negative battery cable and

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

allow vehicle exhaust to cool.

allow vehicle exhaust to cool.

allow vehicle exhaust to cool.

Part s List

A. Head pipe 1
B. Muffler 24" 1
C. Tail pipe 1
D. Turn out 1
E. Front muffler clamp 3" 1
F. Rear muffler clamp/hanger 3" 1

.

.

G. Turn out clamp/hanger 3" 1

.

.

.

8. Spray lubricant on front muffler hanger

8. Spray lubricant on front muffler hanger

8. Spray lubricant on front muffler hanger

8. Spray lubricant on front muffler hanger
grommet.

grommet.

grommet.

grommet.

E

A

15. With the JBA logo to the rear of the

15. With the JBA logo to the rear of the

15. With the JBA logo to the rear of the

15. With the JBA logo to the rear of the
vehicle, slip muffler (B) on head pipe (A).

vehicle, slip muffler (B) on head pipe (A).

vehicle, slip muffler (B) on head pipe (A).

vehicle, slip muffler (B) on head pipe (A).

NOTE: You may have to tap it with a

NOTE: You may have to tap it with a

NOTE: You may have to tap it with a

NOTE: You may have to tap it with a

rubber mallet.

rubber mallet.

rubber mallet.

rubber mallet.

B

F

C

22. Install turnout (D) slip joint over end

22. Install turnout (D) slip joint over end

22. Install turnout (D) slip joint over end

22. Install turnout (D) slip joint over end
of tail pipe (C).

of tail pipe (C).

of tail pipe (C).

of tail pipe (C).

G

D

3. With vehicle raised and properly sup-

3. With vehicle raised and properly sup-

3. With vehicle raised and properly sup-

3. With vehicle raised and properly sup­ported, using a reciprocating saw or hack

ported, using a reciprocating saw or hack

ported, using a reciprocating saw or hack

ported, using a reciprocating saw or hack
saw, cut the tail pipe approximately 1"

saw, cut the tail pipe approximately 1"

saw, cut the tail pipe approximately 1"

saw, cut the tail pipe approximately 1"
behind rear muffler hanger.

behind rear muffler hanger.

behind rear muffler hanger.

behind rear muffler hanger.

4. Spray lubricant on front and rear tail

4. Spray lubricant on front and rear tail

4. Spray lubricant on front and rear tail

4. Spray lubricant on front and rear tail
pipe rubber grommet.

pipe rubber grommet.

pipe rubber grommet.

pipe rubber grommet.

5. Using a pair of channel lock pliers,

5. Using a pair of channel lock pliers,

5. Using a pair of channel lock pliers,

5. Using a pair of channel lock pliers,
remove hanger rods from bottom holes of

remove hanger rods from bottom holes of

remove hanger rods from bottom holes of

remove hanger rods from bottom holes of
front and rear tailpipe rubber grommets.

front and rear tailpipe rubber grommets.

front and rear tailpipe rubber grommets.

front and rear tailpipe rubber grommets.

6. Remove tail pipe assembly from the

6. Remove tail pipe assembly from the

6. Remove tail pipe assembly from the

6. Remove tail pipe assembly from the
rear of vehicle.

rear of vehicle.

rear of vehicle.

rear of vehicle.

9. With muffler and head pipe properly

9. With muffler and head pipe properly

9. With muffler and head pipe properly

9. With muffler and head pipe properly
supported, using a pair of channel lock

supported, using a pair of channel lock

supported, using a pair of channel lock

supported, using a pair of channel lock
pliers, remove hanger rod from bottom

pliers, remove hanger rod from bottom

pliers, remove hanger rod from bottom

pliers, remove hanger rod from bottom
hole of grommet.

hole of grommet.

hole of grommet.

hole of grommet.

10. Remove muffler and head pipe

10. Remove muffler and head pipe

10. Remove muffler and head pipe

10. Remove muffler and head pipe
assembly.

assembly.

assembly.

assembly.

11. Install head pipe (A) hanger into

11. Install head pipe (A) hanger into

11. Install head pipe (A) hanger into

11. Install head pipe (A) hanger into
bottom hole of rubber grommet.

bottom hole of rubber grommet.

bottom hole of rubber grommet.

bottom hole of rubber grommet.

12. Install head pipe over studs and install

12. Install head pipe over studs and install

12. Install head pipe over studs and install

12. Install head pipe over studs and install
flange nuts and align flange. using a

flange nuts and align flange. using a

flange nuts and align flange. using a

flange nuts and align flange. using a
15mm socket and ratchet, tighten nuts

15mm socket and ratchet, tighten nuts

15mm socket and ratchet, tighten nuts

15mm socket and ratchet, tighten nuts
completely. NOTE: we recommend using

completely. NOTE: we recommend using

completely. NOTE: we recommend using

completely. NOTE: we recommend using
anti-seize on threads.

anti-seize on threads.

anti-seize on threads.

anti-seize on threads.

16. Slip rear muffler hanger (F) over rear

16. Slip rear muffler hanger (F) over rear

16. Slip rear muffler hanger (F) over rear

16. Slip rear muffler hanger (F) over rear
slip joint of muffler (B) and hand tighten at

slip joint of muffler (B) and hand tighten at

slip joint of muffler (B) and hand tighten at

slip joint of muffler (B) and hand tighten at
this time.

this time.

this time.

this time.

17. Position 3" clamp (E) on muffler (B)

17. Position 3" clamp (E) on muffler (B)

17. Position 3" clamp (E) on muffler (B)

17. Position 3" clamp (E) on muffler (B)
and using a 9/16" deep socket, tighten

and using a 9/16" deep socket, tighten

and using a 9/16" deep socket, tighten

and using a 9/16" deep socket, tighten
completely.

completely.

completely.

completely.

18. Install tail pipe (C) into rear slip joint

18. Install tail pipe (C) into rear slip joint

18. Install tail pipe (C) into rear slip joint

18. Install tail pipe (C) into rear slip joint
on muffler (B). NOTE: tail pipe (C)

on muffler (B). NOTE: tail pipe (C)

on muffler (B). NOTE: tail pipe (C)

on muffler (B). NOTE: tail pipe (C)
should be installed with the hanger to

should be installed with the hanger to

should be installed with the hanger to

should be installed with the hanger to
the rear of the vehicle.

the rear of the vehicle.

the rear of the vehicle.

the rear of the vehicle.

19. Install tail pipe (C) hanger rod into

19. Install tail pipe (C) hanger rod into

19. Install tail pipe (C) hanger rod into

19. Install tail pipe (C) hanger rod into
bottom hole of rear rubber hanger

bottom hole of rear rubber hanger

bottom hole of rear rubber hanger

bottom hole of rear rubber hanger
grommet.

grommet.

grommet.

grommet.

NOTE: use anti-seize on threads.

NOTE: use anti-seize on threads.

NOTE: use anti-seize on threads.

NOTE: use anti-seize on threads.

23. Position turnout (D) to desired position.

23. Position turnout (D) to desired position.

23. Position turnout (D) to desired position.

23. Position turnout (D) to desired position.

24. Position 3" clamp (I) over turnout (D)

24. Position 3" clamp (I) over turnout (D)

24. Position 3" clamp (I) over turnout (D)

24. Position 3" clamp (I) over turnout (D)
slip joint and tighten completely using a

slip joint and tighten completely using a

slip joint and tighten completely using a

slip joint and tighten completely using a
9/16" deep socket. NOTE: use anti-seize

9/16" deep socket. NOTE: use anti-seize

9/16" deep socket. NOTE: use anti-seize

9/16" deep socket. NOTE: use anti-seize
on threads.

on threads.

on threads.

on threads.

25. After installation, it is recommended

25. After installation, it is recommended

25. After installation, it is recommended

25. After installation, it is recommended
that all clamps be retightened and joints

that all clamps be retightened and joints

that all clamps be retightened and joints

that all clamps be retightened and joints
be tack welded in three spot.

be tack welded in three spot.

be tack welded in three spot.

be tack welded in three spot.

26. Using a soft cloth, remove all prints

26. Using a soft cloth, remove all prints

26. Using a soft cloth, remove all prints

26. Using a soft cloth, remove all prints
from turnout tip.

from turnout tip.

from turnout tip.

from turnout tip.

27. Lower vehicle and reattach the

27. Lower vehicle and reattach the

27. Lower vehicle and reattach the

27. Lower vehicle and reattach the
negative battery cable.

negative battery cable.

negative battery cable.

negative battery cable.

28. Run vehicle until exhaust reaches

28. Run vehicle until exhaust reaches

28. Run vehicle until exhaust reaches

28. Run vehicle until exhaust reaches
operating temperature and retighten the

operating temperature and retighten the

operating temperature and retighten the

operating temperature and retighten the
two 15mm flange nuts.

two 15mm flange nuts.

two 15mm flange nuts.

two 15mm flange nuts.

NOTES:

NOTES:

NOTES:

NOTES:

1) All exhaust systems will expand about

1) All exhaust systems will expand about

1) All exhaust systems will expand about

1) All exhaust systems will expand about
1" rearward when exhaust temperature

1" rearward when exhaust temperature

1" rearward when exhaust temperature

1" rearward when exhaust temperature
start to rise.

start to rise.

start to rise.

start to rise.

2) Use Anti-seize on threads of clamps E,

2) Use Anti-seize on threads of clamps E,

2) Use Anti-seize on threads of clamps E,

2) Use Anti-seize on threads of clamps E,
F and G.

F and G.

F and G.

F and G.

13. Install 3" clamp (E) over head pipe (A).

13. Install 3" clamp (E) over head pipe (A).

13. Install 3" clamp (E) over head pipe (A).

13. Install 3" clamp (E) over head pipe (A).

7. Using a 15mm socket and ratchet,

7. Using a 15mm socket and ratchet,

7. Using a 15mm socket and ratchet,

7. Using a 15mm socket and ratchet,
remove flange nuts from head pipe.

remove flange nuts from head pipe.

remove flange nuts from head pipe.

remove flange nuts from head pipe.

14. Install rear muffler hanger clamp (F)

14. Install rear muffler hanger clamp (F)

14. Install rear muffler hanger clamp (F)

14. Install rear muffler hanger clamp (F)
into the bottom hole of rear muffler

into the bottom hole of rear muffler

into the bottom hole of rear muffler

into the bottom hole of rear muffler
hanger rubber grommet.

hanger rubber grommet.

hanger rubber grommet.

hanger rubber grommet.

We recommend taking the truck to a muffler shop and having all slip connections tack welded.

We recommend taking the truck to a muffler shop and having all slip connections tack welded.

We recommend taking the truck to a muffler shop and having all slip connections tack welded.

We recommend taking the truck to a muffler shop and having all slip connections tack welded.

20. With tail pipe (C) aligned to desired

20. With tail pipe (C) aligned to desired

20. With tail pipe (C) aligned to desired

20. With tail pipe (C) aligned to desired
position, using a 9/16" deep socket,

position, using a 9/16" deep socket,

position, using a 9/16" deep socket,

position, using a 9/16" deep socket,
tighten nuts on rear muffler hanger (F)

tighten nuts on rear muffler hanger (F)

tighten nuts on rear muffler hanger (F)

tighten nuts on rear muffler hanger (F)
completely.

completely.

completely.

completely.

NOTE: use anti-seize on threads.

NOTE: use anti-seize on threads.

NOTE: use anti-seize on threads.

NOTE: use anti-seize on threads.

21. Install 3" clamp (G) over end of tail

21. Install 3" clamp (G) over end of tail

21. Install 3" clamp (G) over end of tail

21. Install 3" clamp (G) over end of tail
pipe (C).

pipe (C).

pipe (C).

pipe (C).

04/18/07