PerTronix 40-3028 User Manual

INSTALLATION INSTRUCTIONSINSTALLATION INSTRUCTIONSINSTALLATION INSTRUCTIONS

INSTALLATION INSTRUCTIONS

**Installation recommendation:

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

40-3028

96-00 Chevrolet Tahoe / GMC Yukon
4 Door, V-8 5.7L 2/4 wd

TTTT OOLS RECOMMENDED:

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

TTTT OOOO STSTSTSTARTARTARTART::::

1. Remove and inventory new Evolª1. Remove and inventory new Evolª1. Remove and inventory new Evolª1. Remove and inventory new Evolª
exhaust.exhaust.exhaust.exhaust.

2. Disconnect negative battery cable and2. Disconnect negative battery cable and2. Disconnect negative battery cable and2. 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.

Parts List

A. Head pipe 1
B. Muffler 24" 1
C. Tail pipe with 1
D. Turn out with hanger 1
E. Front muffler clamp/hanger 3" 1
F... 3" clamp 2

8. S8. S8. S8. Spray lubricant on front mufpray lubricant on front mufpray lubricant on front mufpray lubricant on front muffler hangerfler hangerfler hangerfler hanger
grommet.grommet.grommet.grommet.

D

C

F

14. With the JBA logo to the rear of the
vehicle, slip mufvehicle, slip mufvehicle, slip muf

vehicle, slip muf

NONONO

TE:TE:TE: YYYY

NO

TE:

rubber mallet.rubber mallet.rubber mallet.

rubber mallet.

fler (B) on head pipe (A).fler (B) on head pipe (A).fler (B) on head pipe (A).

fler (B) on head pipe (A).

ou may have to tou may have to tou may have to t

ou may have to t

F

ap it with aap it with aap it with a

ap it with a

A

B

E

20. Install turnout (D) slip joint over endall turnout (D) slip joint over endall turnout (D) slip joint over endall turnout (D) slip joint over end
of tof tof tof tail pipe (C).ail pipe (C).ail pipe (C).ail pipe (C).

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 hackported, using a reciprocating saw or hackported, using a reciprocating saw or hackported, using a reciprocating saw or hack
sawsawsawsaw, cut the t, cut the t, cut the t, cut the tail pipe approximately 1"ail pipe approximately 1"ail pipe approximately 1"ail pipe approximately 1"

behind rear mufbehind rear mufbehind rear mufbehind rear muffler hangerfler hangerfler hangerfler hanger....

4. S4. S4. S4. Spray lubricant on front and rear tpray lubricant on front and rear tpray lubricant on front and rear tpray lubricant on front and rear tailailailail
pipe rubber grommet.pipe rubber grommet.pipe rubber grommet.pipe rubber grommet.

5. Using a p5. Using a p5. Using a p5. Using a pair of channel lock pliers,air of channel lock pliers,air of channel lock pliers,air of channel lock pliers,
remove hanger rods from bottom holes ofremove hanger rods from bottom holes ofremove hanger rods from bottom holes ofremove hanger rods from bottom holes of
front and rear tfront and rear tfront and rear tfront and rear tailpipe rubber grommetailpipe rubber grommetailpipe rubber grommetailpipe rubber grommets.s.s.s.

9. With muf9. With muf9. With muf9. With muffler and head pipe properlyfler and head pipe properlyfler and head pipe properlyfler and head pipe properly
supported, using a psupported, using a psupported, using a psupported, using a pair of channel lockair of channel lockair of channel lockair of channel lock
pliers, remove hanger rod from bottompliers, remove hanger rod from bottompliers, remove hanger rod from bottompliers, remove hanger rod from bottom
hole of grommet.hole of grommet.hole of grommet.hole of grommet.

10. Remove muf10. Remove muf10. Remove muf10. Remove muffler and head pipefler and head pipefler and head pipefler and head pipe

assemblyassemblyassemblyassembly....

all head pipe (G) hanger into

11111. Inst1. Inst1. Inst1. Inst
bottom hole of rubber grommet.bottom hole of rubber grommet.bottom hole of rubber grommet.bottom hole of rubber grommet.

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

and using a 9/16" deep socket, tighten

completelycompletelycompletely....

completely

16. Install tall tall tall tail pipe (C) into rear slip jointail pipe (C) into rear slip jointail pipe (C) into rear slip jointail pipe (C) into rear slip joint
on mufon mufon mufon muffler (B).fler (B).fler (B).fler (B). NONONONOTE:TE:TE:TE: ttttail pipe (C)ail pipe (C)ail pipe (C)ail pipe (C)
should be instshould be instshould be instshould be installed with the hanger toalled with the hanger toalled with the hanger toalled with the hanger to
the rear of the vehicle.the rear of the vehicle.the rear of the vehicle.the rear of the vehicle.

17. Install tall tall tall tail pipe (C) hanger rod intoail pipe (C) hanger rod intoail pipe (C) hanger rod intoail pipe (C) hanger rod into
bottom hole of rear rubber hangerbottom hole of rear rubber hangerbottom hole of rear rubber hangerbottom hole of rear rubber hanger
grommet.grommet.grommet.grommet.

NONONONOTE:TE:TE:TE: use anti-seize on threads.use anti-seize on threads.use anti-seize on threads.use anti-seize on threads.

fler (B)fler (B)fler (B)

21. Position turnout (D) to desired positio

22. Position 3" clamp (I) over turnout (D)
slip joint and tighten completely using aslip joint and tighten completely using aslip joint and tighten completely using aslip joint and tighten completely using a
9/16" deep socket.9/16" deep socket.9/16" deep socket.9/16" deep socket. NONONONOTE:TE:TE:TE: use anti-seizeuse anti-seizeuse anti-seizeuse anti-seize
on threads.on threads.on threads.on threads.

23.

AfAfAfAfter instter instter instter installation, it is recommendedallation, it is recommendedallation, it is recommendedallation, it is recommended
that all clampthat all clampthat all clampthat all clamps be retightened and joints be retightened and joints be retightened and joints be retightened and jointssss
be tbe tbe tbe tack welded in three spot.ack welded in three spot.ack welded in three spot.ack welded in three spot.

24. Using a soft cloth, remove all printt cloth, remove all printt cloth, remove all printt cloth, remove all printssss
from turnout tip.from turnout tip.from turnout tip.from turnout tip.

25. Lower vehicle and reatt
negative battery cable.negative battery cable.negative battery cable.negative battery cable.

26. Run vehicle until exhaust reaches
operating temperature and retighten theoperating temperature and retighten theoperating temperature and retighten theoperating temperature and retighten the
two 15mm flange nuttwo 15mm flange nuttwo 15mm flange nuttwo 15mm flange nuts.s.s.s.

NONONONOTES:TES:TES:TES:

1)1)1)1) All exhaust systems will expAll exhaust systems will expAll exhaust systems will expAll exhaust systems will expand aboutand aboutand aboutand about
1" rearward when exhaust temperature1" rearward when exhaust temperature1" rearward when exhaust temperature1" rearward when exhaust temperature
ststststart to rise.art to rise.art to rise.art to rise.

2) Use2) Use2) Use2) Use Anti-seize on threads of clampAnti-seize on threads of clampAnti-seize on threads of clampAnti-seize on threads of clamps E,s E,s E,s E

F and GF and GF and GF and G....

ach theach theach theach the

n.

,

12. Inst12. Inst12. Inst12. Install head pipe over studs and install head pipe over studs and install head pipe over studs and install head pipe over studs and inst
flange nutflange nutflange nutflange nuts and align flange. using as and align flange. using as and align flange. using as and align flange. using a

6. Remove t6. Remove t6. Remove t6. Remove tail pipe assembly from theail pipe assembly from theail pipe assembly from theail pipe assembly from the
rear of vehicle.rear of vehicle.rear of vehicle.rear of vehicle.

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 nutremove flange nutremove flange nutremove flange nuts from head pipe.s from head pipe.s from head pipe.s from head pipe.

WWWW eeee rrrrececececommend takommend takommend takommend taking the truck ting the truck ting the truck ting the truck to a muffler shop and hao a muffler shop and hao a muffler shop and hao a muffler shop and having all slip cving all slip cving all slip cving all slip conneconneconneconnections tack wtions tack wtions tack wtions tack weldedeldedeldedelded....

15mm socket and ratchet, tighten nut15mm socket and ratchet, tighten nut15mm socket and ratchet, tighten nut15mm socket and ratchet, tighten nutssss

completelycompletelycompletelycompletely.... NONONONOTE:TE:TE:TE: we recommend usingwe recommend usingwe recommend usingwe recommend using

anti-seize on threads.anti-seize on threads.anti-seize on threads.anti-seize on threads.

13. Install 3" clamp with hanger (G) over
head pipe (A).

all

18. With tail pipe (C) aligned to desiredail pipe (C) aligned to desiredail pipe (C) aligned to desiredail 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 nuttighten nuttighten nuttighten nuts on rear mufs on rear mufs on rear mufs on rear muffler hanger (F)fler hanger (F)fler hanger (F)fler hanger (F)

completelycompletelycompletelycompletely....

NONONONOTE:TE:TE:TE: use anti-seize on threads.use anti-seize on threads.use anti-seize on threads.use anti-seize on threads.

19. Install 3" clamp (G) over end of tall 3" clamp (G) over end of tall 3" clamp (G) over end of tall 3" clamp (G) over end of tailailailail
pipe (C).pipe (C).pipe (C).pipe (C).

04/07