PerTronix 40-3040 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.
40-3040
01-02 Chevrolet Tahoe / GMC Yukon
V-8 4.8/5.3L 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 22" 1
C. Tail pipe with 1
D. Turn out with hanger 1
E. Front muffler clamp/hanger 3" 1
F. 3" clamp 2
.
.
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.
C
F
D
14. 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.
F
B
E
20. Install turnout (D) slip joint over end
all turnout (D) slip joint over end
all turnout (D) slip joint over end
all turnout (D) slip joint over end
of tail pipe (C).
of tail pipe (C).
of tail pipe (C).
of tail pipe (C).
A
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 (E) hanger into
11. Inst
11. Inst
11. Inst
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 inst
12. Install head pipe over studs and inst
12. Install head pipe over studs and inst
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.
15. Position 3" clamp (F) 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.
16. 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.
17. 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.
18. 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.
NOTE: use anti-seize on threads.
NOTE: use anti-seize on threads.
NOTE: use anti-seize on threads.
NOTE: use anti-seize on threads.
all tail pipe (C) into rear slip joint
all tail pipe (C) into rear slip joint
all tail pipe (C) into rear slip joint
all tail pipe (C) hanger rod into
all tail pipe (C) hanger rod into
all tail pipe (C) hanger rod into
ail pipe (C) aligned to desired
ail pipe (C) aligned to desired
ail pipe (C) aligned to desired
fler (B)
fler (B)
fler (B)
21. Position turnout (D) to desired position.
22. 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.
23. After installation, it is recommended
After installation, it is recommended
After installation, it is recommended
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.
24. Using a soft cloth, remove all prints
from turnout tip.
from turnout tip.
from turnout tip.
from turnout tip.
25. Lower vehicle and reattach the
negative battery cable.
negative battery cable.
negative battery cable.
negative battery cable.
26. 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.
t cloth, remove all prints
t cloth, remove all prints
t cloth, remove all prints
ach the
ach the
ach the
13. Install 3" clamp with hanger (E) over
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.
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.
head pipe (A).
19. Install 3" clamp (G) over end of tail
all 3" clamp (G) over end of tail
all 3" clamp (G) over end of tail
all 3" clamp (G) over end of tail
pipe (C).
pipe (C).
pipe (C).
pipe (C).
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