Instruction Manual

INSTALLATION INSTRUCTIONSINSTALLATION INSTRUCTIONSINSTALLATION INSTRUCTIONSINSTALLATION INSTRUCTIONS

**Inst**Inst**Inst**Inst allation recommendation:allation recommendation:allation recommendation:allation recommendation:

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

40-3003

GM PickupGM PickupGM PickupGM Pickup

96-98 V8-5.7L96-98 V8-5.7L96-98 V8-5.7L96-98 V8-5.7L SSSSttttd. cab, Sd. cab, Sd. cab, Sd. cab, Sttttd. bedd. bedd. bedd. bed

PartPartPartPart s Lists Lists Lists List

TTTTOOLS RECOMMENDED:OOLS RECOMMENDED:OOLS RECOMMENDED:OOLS RECOMMENDED:

A.A.A.A. Head pipe with hangerHead pipe with hangerHead pipe with hangerHead pipe with hanger 1111

reciprocating saw or hack sawreciprocating saw or hack sawreciprocating saw or hack sawreciprocating saw or hack saw

B.B.B.B. MufMufMufMuffler 24"fler 24"fler 24"fler 24" 1111

prybarprybarprybarprybar

C.C.C.C. TTTTail pipe with hangerail pipe with hangerail pipe with hangerail pipe with hanger 1111

rubber malletrubber malletrubber malletrubber mallet

D.D.D.D. TTTTurn outurn outurn outurn out 1111

ratchetratchetratchetratchet

E.E.E.E. Front mufFront mufFront mufFront muffler clamp 3"fler clamp 3"fler clamp 3"fler clamp 3" 1111

15mm deep socket15mm deep socket15mm deep socket15mm deep socket

FFFF.... Rear mufRear mufRear mufRear muffler clamp/hanger 3"fler clamp/hanger 3"fler clamp/hanger 3"fler clamp/hanger 3" 1111

9/16 box wrench or socket9/16 box wrench or socket9/16 box wrench or socket9/16 box wrench or socket

GGGG.... TTTTurn out clamp 3"urn out clamp 3"urn out clamp 3"urn out clamp 3" 1111

7/8" open end wrench7/8" open end wrench7/8" open end wrench7/8" open end wrench

ppppair of channel lock pliersair of channel lock pliersair of channel lock pliersair of channel lock pliers

13mm socket13mm socket13mm socket13mm socket

CCCC

anti-seizeanti-seizeanti-seizeanti-seize

impimpimpimpact wrenchact wrenchact wrenchact wrench

TTTT OOOO STSTSTST ARTARTARTART ::::

spray lubricant or penetrating oilspray lubricant or penetrating oilspray lubricant or penetrating oilspray lubricant or penetrating oil

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.

1. Remove and inventory new JBA1. Remove and inventory new JBA1. Remove and inventory new JBA1. Remove and inventory new JBA

exhaust.exhaust.exhaust.exhaust.

9. Remove three nut9. Remove three nut9. Remove three nut9. Remove three nuts on three bolt flanges on three bolt flanges on three bolt flanges on three bolt flange

using 15mm socket.using 15mm socket.using 15mm socket.using 15mm socket. YYYYou may want to useou may want to useou may want to useou may want to use

some penetrating oil.some penetrating oil.some penetrating oil.some penetrating oil.

15. With muf15. With muf15. With muf15. With muffler (B) in place, instfler (B) in place, instfler (B) in place, instfler (B) in place, install muf-all muf-all muf-all muf-

fler clamp (E) on slip fit joint. Position 1/4"fler clamp (E) on slip fit joint. Position 1/4"fler clamp (E) on slip fit joint. Position 1/4"fler clamp (E) on slip fit joint. Position 1/4"

from lip.from lip.from lip.from lip. TTTTighten clamp completely withighten clamp completely withighten clamp completely withighten clamp completely with

9/16" deep wall socket. NOTE: Use some9/16" deep wall socket. NOTE: Use some9/16" deep wall socket. NOTE: Use some9/16" deep wall socket. NOTE: Use some

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

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 sup-

ported, 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 3"ail pipe approximately 3"ail pipe approximately 3"ail pipe approximately 3"

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

10. Using a p10. Using a p10. Using a p10. Using a pair of channel lock pliers,air of channel lock pliers,air of channel lock pliers,air of channel lock pliers,

remove front and rear mufremove front and rear mufremove front and rear mufremove front and rear muffler hanger rodsfler hanger rodsfler hanger rodsfler hanger rods

from bottom holes of grommetfrom bottom holes of grommetfrom bottom holes of grommetfrom bottom holes of grommets.s.s.s.

Note:Note:Note:Note: support mufsupport mufsupport mufsupport muffler before stfler before stfler before stfler before starting.arting.arting.arting.

16. Inst16. Inst16. Inst16. Install rear mufall rear mufall rear mufall rear muffler clamp/hanger (F)fler clamp/hanger (F)fler clamp/hanger (F)fler clamp/hanger (F)

over slip joint on rear of mufover slip joint on rear of mufover slip joint on rear of mufover slip joint on rear of mufflerflerflerfler. Do not. Do not. Do not. Do not

tighten at this time.tighten at this time.tighten at this time.tighten at this time.

22. Position rear muf22. Position rear muf22. Position rear muf22. Position rear muffler clamp/hanger (F)fler clamp/hanger (F)fler clamp/hanger (F)fler clamp/hanger (F)

1/4" from lip on slip joint and tighten com-1/4" from lip on slip joint and tighten com-1/4" from lip on slip joint and tighten com-1/4" from lip on slip joint and tighten com-

pletely with 9/16" deep wall socket. Note:pletely with 9/16" deep wall socket. Note:pletely with 9/16" deep wall socket. Note:pletely with 9/16" deep wall socket. Note:

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

4. S4. S4. S4. Spray lubricant on rear tpray lubricant on rear tpray lubricant on rear tpray lubricant on rear tail pipe hangerail pipe hangerail pipe hangerail pipe hanger

grommet.grommet.grommet.grommet.

11111. Remove muf1. Remove muf1. Remove muf1. Remove muffler assembly pullingfler assembly pullingfler assembly pullingfler assembly pulling

towards rear of vehicle. Note: use care nottowards rear of vehicle. Note: use care nottowards rear of vehicle. Note: use care nottowards rear of vehicle. Note: use care not

to damage gasket on three bolt flange.to damage gasket on three bolt flange.to damage gasket on three bolt flange.to damage gasket on three bolt flange.

17. Slip clamp/hanger (F) into lower hole17. Slip clamp/hanger (F) into lower hole17. Slip clamp/hanger (F) into lower hole17. Slip clamp/hanger (F) into lower hole

on rubber grommet.on rubber grommet.on rubber grommet.on 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 rod from bottom hole ofremove hanger rod from bottom hole ofremove hanger rod from bottom hole ofremove hanger rod from bottom hole of

grommet.grommet.grommet.grommet.

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.

8. Remove oxygen sensor with 7/8" open8. Remove oxygen sensor with 7/8" open8. Remove oxygen sensor with 7/8" open8. Remove oxygen sensor with 7/8" open

end wrench.end wrench.end wrench.end wrench.

7. S7. S7. S7. Spray lubricant on front and rear mufpray lubricant on front and rear mufpray lubricant on front and rear mufpray lubricant on front and rear mufflerflerflerfler

hanger grommethanger grommethanger grommethanger grommets.s.s.s.

12. Inst12. Inst12. Inst12. Install head pipe (A) with three boltall head pipe (A) with three boltall head pipe (A) with three boltall head pipe (A) with three bolt

flange. Instflange. Instflange. Instflange. Install hanger through lower holeall hanger through lower holeall hanger through lower holeall hanger through lower hole

in rubber grommet.in rubber grommet.in rubber grommet.in rubber grommet. TTTTighten three nutighten three nutighten three nutighten three nutssss

using 15mm socket.using 15mm socket.using 15mm socket.using 15mm socket. Note:Note:Note:Note: we recom-we recom-we recom-we recom-

mend using anti-seize on threads.mend using anti-seize on threads.mend using anti-seize on threads.mend using anti-seize on threads.

13. Inst13. Inst13. Inst13. Install oxygen sensor using 7/8"all oxygen sensor using 7/8"all oxygen sensor using 7/8"all oxygen sensor using 7/8"

wrench.wrench.wrench.wrench.

14. Slip muf14. Slip muf14. Slip muf14. Slip muffler (B) on head pipe approxi-fler (B) on head pipe approxi-fler (B) on head pipe approxi-fler (B) on head pipe approxi-

mately 2". Note:mately 2". Note:mately 2". Note:mately 2". Note: YYYYou may have to tou may have to tou may have to tou may have to tap it inap it inap it inap it in

with a rubber mallet. Make sure JBA logowith a rubber mallet. Make sure JBA logowith a rubber mallet. Make sure JBA logowith a rubber mallet. Make sure JBA logo

is to the rearis to the rearis to the rearis to the rear....

18. Inst18. Inst18. Inst18. Install tall tall tall tail pipe (C) from rear into slipail pipe (C) from rear into slipail pipe (C) from rear into slipail pipe (C) from rear into slip

joint on mufjoint on mufjoint on mufjoint on muffler (B). Slip approx. 2".fler (B). Slip approx. 2".fler (B). Slip approx. 2".fler (B). Slip approx. 2".

19. Slip rear t19. Slip rear t19. Slip rear t19. Slip rear tail pipe (C) hanger intoail pipe (C) hanger intoail pipe (C) hanger intoail pipe (C) hanger into

lower hole in rubber grommet.lower hole in rubber grommet.lower hole in rubber grommet.lower hole in rubber grommet.

20. Position t20. Position t20. Position t20. Position tail pipe (C) so hanger is notail pipe (C) so hanger is notail pipe (C) so hanger is notail pipe (C) so hanger is not

cocked at an angle, and rubber grommetcocked at an angle, and rubber grommetcocked at an angle, and rubber grommetcocked at an angle, and rubber grommet

is angled forward.is angled forward.is angled forward.is angled forward.

21. Inspect clearance around rear-end21. Inspect clearance around rear-end21. Inspect clearance around rear-end21. Inspect clearance around rear-end

shock and spshock and spshock and spshock and spare tire.are tire.are tire.are tire.

24. Using a sof24. Using a sof24. Using a sof24. 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 reatt25. Lower vehicle and reatt25. Lower vehicle and reatt25. Lower vehicle and reattach the nega-ach the nega-ach the nega-ach the nega-

tive battery cable.tive battery cable.tive battery cable.tive battery cable.

NOTES:NOTES:NOTES:NOTES:

1) It may be necessary to loosen and1) It may be necessary to loosen and1) It may be necessary to loosen and1) It may be necessary to loosen and

realign the sprealign the sprealign the sprealign the spare tire for proper clear-are tire for proper clear-are tire for proper clear-are tire for proper clear-

ance.ance.ance.ance.

2)2)2)2) All exhaust systems will expAll exhaust systems will expAll exhaust systems will expAll exhaust systems will expand aboutand aboutand aboutand about

1î rearward when exhaust temperature1î rearward when exhaust temperature1î rearward when exhaust temperature1î rearward when exhaust temperature

ststststart to rise.art to rise.art to rise.art to rise.

3) Use3) Use3) Use3) Use Anti-seize on threads of clampAnti-seize on threads of clampAnti-seize on threads of clampAnti-seize on threads of clamps D,s D,s D,s D,

E and FE and FE and FE and F....

23. Slip turn out clamp (G) onto t23. Slip turn out clamp (G) onto t23. Slip turn out clamp (G) onto t23. Slip turn out clamp (G) onto tail pipe.ail pipe.ail pipe.ail pipe.

Slip turn out (D) on tSlip turn out (D) on tSlip turn out (D) on tSlip turn out (D) on tail pipe (C) approx.ail pipe (C) approx.ail pipe (C) approx.ail pipe (C) approx.

1-1/2î. Rot1-1/2î. Rot1-1/2î. Rot1-1/2î. Rotate tip to desired position leav-ate tip to desired position leav-ate tip to desired position leav-ate tip to desired position leav-

ing clearance from bodying clearance from bodying clearance from bodying clearance from body. Position clamp. Position clamp. Position clamp. Position clamp

(G) with threads in an upward position.(G) with threads in an upward position.(G) with threads in an upward position.(G) with threads in an upward position.

TTTTighten completely with 9/16" deep wallighten completely with 9/16" deep wallighten completely with 9/16" deep wallighten completely with 9/16" deep wall

socket. Note: use anti-seize on threads.socket. Note: use anti-seize on threads.socket. Note: use anti-seize on threads.socket. Note: use anti-seize on threads.

17092170921709217092

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

4/17/07