PerTronix 40-3015 User Manual
INSTALLATION INSTRUCTIONS
40-3015
GM Avalanche
2002 V8 - 5.3L
T OOLS RECOMMENDED:
TO START :
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
2. Disconnect negative battery cable and
allow vehicle exhaust to cool.
3. With vehicle raised and properly supported, using a reciprocating saw or hack
saw, cut the tail pipe approximately 1"
behind rear muffler hanger.
4. Spray lubricant on front and rear tail
pipe rubber grommet.
INSTALLATION INSTRUCTIONS
T OOLS RECOMMENDED:
TO START :
p
2. Disconnect negative battery cable and
allow vehicle exhaust to cool.
3. With vehicle raised and properly supported, using a reciprocating saw or hack
saw, cut the tail pipe approximately 1"
behind rear muffler hanger.
4. Spray lubricant on front and rear tail
pipe rubber grommet.
INSTALLATION INSTRUCTIONS
T OOLS RECOMMENDED:
TO START :
p
2. Disconnect negative battery cable and
allow vehicle exhaust to cool.
3. With vehicle raised and properly supported, using a reciprocating saw or hack
saw, cut the tail pipe approximately 1"
behind rear muffler hanger.
4. Spray lubricant on front and rear tail
pipe rubber grommet.
INSTALLATION INSTRUCTIONS
T OOLS RECOMMENDED:
TO START :
p
2. Disconnect negative battery cable and
allow vehicle exhaust to cool.
3. With vehicle raised and properly supported, using a reciprocating saw or hack
saw, cut the tail pipe approximately 1"
behind rear muffler hanger.
4. Spray lubricant on front and rear tail
pipe rubber grommet.
5. Using a pair of channel lock pliers,
remove hanger rods from bottom holes of
front and rear tailpipe rubber grommets.
9. With muffler and head pipe properly
supported, using a pair of channel lock
pliers, remove hanger rod from bottom
hole of grommet.
1. Remove and inventory new Evol™
exhaust.
10. Remove muffler and head pipe
assembly.
6. Remove tail pipe assembly from the
rear of vehicle.
11. Install head pipe (A) hanger into
bottom hole of rubber grommet.
15. With the JBA logo to the rear of the
vehicle, slip muffler (B) on head pipe (A).
NOTE: You may have to tap it with a
rubber mallet.
14. Slip front muffler hanger (F) over front
slip joint of muffler (B) and hand tighten at
this time.
25. Lower vehicle and reattach the
negative battery cable.
26. Run vehicle until exhaust reaches
operating temperature and retighten the
two 15mm flange nuts.
NOTES:
1) All exhaust systems will expand about
1" rearward when exhaust temperature
start to rise.
2) Use Anti-seize on threads of clamps E,
F and G.
12. Install head pipe over studs and install
flange nuts and align flange. using a
15mm socket and ratchet, tighten nuts
completely. NOTE: we recommend using
anti-seize on threads.
13. Install front muffler hanger clamp (F)
into the bottom hole of front muffler
hanger rubber grommet.
8. Spray lubricant on front muffler hanger
grommet.
5. Using a pair of channel lock pliers,
remove hanger rods from bottom holes of
front and rear tailpipe rubber grommets.
9. With muffler and head pipe properly
supported, using a pair of channel lock
pliers, remove hanger rod from bottom
hole of grommet.
1. Remove and inventory new Evol™
exhaust.
10. Remove muffler and head pipe
assembly.
6. Remove tail pipe assembly from the
rear of vehicle.
11. Install head pipe (A) hanger into
bottom hole of rubber grommet.
15. With the JBA logo to the rear of the
vehicle, slip muffler (B) on head pipe (A).
NOTE: You may have to tap it with a
rubber mallet.
slip joint of muffler (B) and hand tighten at
this time.
ach the
negative battery cable.
operating temperature and retighten the
two 15mm flange nuts.
NOTES:
1) All exhaust systems will expand about
1" rearward when exhaust temperature
start to rise.
2) Use Anti-seize on threads of clamps E,
F and G.
12. Install head pipe over studs and install
flange nuts and align flange. using a
15mm socket and ratchet, tighten nuts
completely. NOTE: we recommend using
anti-seize on threads.
8. Spray lubricant on front muffler hanger
grommet.
5. Using a pair of channel lock pliers,
remove hanger rods from bottom holes of
front and rear tailpipe rubber grommets.
9. With muffler and head pipe properly
supported, using a pair of channel lock
pliers, remove hanger rod from bottom
hole of grommet.
1. Remove and inventory new Evol™
exhaust.
10. Remove muffler and head pipe
assembly.
6. Remove tail pipe assembly from the
rear of vehicle.
11. Install head pipe (A) hanger into
bottom hole of rubber grommet.
15. With the JBA logo to the rear of the
vehicle, slip muffler (B) on head pipe (A).
NOTE: You may have to tap it with a
rubber mallet.
slip joint of muffler (B) and hand tighten at
this time.
ach the
negative battery cable.
operating temperature and retighten the
two 15mm flange nuts.
NOTES:
1) All exhaust systems will expand about
1" rearward when exhaust temperature
start to rise.
2) Use Anti-seize on threads of clamps E,
F and G.
12. Install head pipe over studs and install
flange nuts and align flange. using a
15mm socket and ratchet, tighten nuts
completely. NOTE: we recommend using
anti-seize on threads.
8. Spray lubricant on front muffler hanger
grommet.
5. Using a pair of channel lock pliers,
remove hanger rods from bottom holes of
front and rear tailpipe rubber grommets.
9. With muffler and head pipe properly
supported, using a pair of channel lock
pliers, remove hanger rod from bottom
hole of grommet.
1. Remove and inventory new Evol™
exhaust.
10. Remove muffler and head pipe
assembly.
6. Remove tail pipe assembly from the
rear of vehicle.
11. Install head pipe (A) hanger into
bottom hole of rubber grommet.
15. With the JBA logo to the rear of the
vehicle, slip muffler (B) on head pipe (A).
NOTE: You may have to tap it with a
rubber mallet.
slip joint of muffler (B) and hand tighten at
this time.
ach the
negative battery cable.
operating temperature and retighten the
two 15mm flange nuts.
NOTES:
1) All exhaust systems will expand about
1" rearward when exhaust temperature
start to rise.
2) Use Anti-seize on threads of clamps E,
F and G.
12. Install head pipe over studs and install
flange nuts and align flange. using a
15mm socket and ratchet, tighten nuts
completely. NOTE: we recommend using
anti-seize on threads.
8. Spray lubricant on front muffler hanger
grommet.
7. Using a 15mm socket and ratchet,
remove flange nuts from head pipe.
7. Using a 15mm socket and ratchet,
remove flange nuts from head pipe.
7. Using a 15mm socket and ratchet,
remove flange nuts from head pipe.
7. Using a 15mm socket and ratchet,
remove flange nuts from head pipe.
W e recommend taking the truck to a muffler shop and having all slip connections tack welded.
Part s List
A. Head pipe 1
B. Muffler 24" 1
C. Tail pipe with hanger 1
D. Turn out 1
E. Front muffler clamp 3" 1
F. Rear muffler clamp 3" 1
G. Turn out clamp 3" 1
**Installation recommendation:
JBA recommends in most cases that the vehicle be taken to a reputable exhaust shop.
W e recommend taking the truck to a muffler shop and having all slip connections tack welded.
Part s List
A. 1
B. 1
C. Tail pipe with hanger 1
D. Turn out 1
E. Front muffler clamp 3" 1
F. Rear muf 1
G. Turn out clamp 3" 1
W e recommend taking the truck to a muffler shop and having all slip connections tack welded.
Part s List
A. 1
B. 1
C. Tail pipe with hanger 1
D. Turn out 1
E. Front muffler clamp 3" 1
F. Rear muf 1
G. Turn out clamp 3" 1
W e recommend taking the truck to a muffler shop and having all slip connections tack welded.
s List
A. 1
B. 1
C. Tail pipe with hanger 1
D. Turn out 1
E. Front muffler clamp 3" 1
F. Rear muf 1
G. Turn out clamp 3" 1
E
F
A
C
B
G
D
17024
E
F
A
C
B
G
D
17024
E
F
A
C
B
G
D
17024
E
F
C
B
G
D
17024
16. Install the front tail pipe hanger into
bottom hole of rubber grommet.
17. Install the new tail pipe with hanger (C)
into the muffler.
18.
grommet.
19.
Note: Use anti-seize on threads.
20.
seize on threads.
21. Position turn out to desired position.
22.
on threads.
be tack welded in three spots.
from turn out tip.
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