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2003 Dodge Ram Regular cab 5.7L Hemi 2/4wd JBA Headers Installation Instructions

November 29th, 2009 · No Comments

TO START:
1. Remove and inventory JBA exhaust
2. Disconnect negative battery cable and allow vehicle exhaust to cool.
3. With the vehicle raised and properly supported, using the 15mm socket and ratchet, loosen the clamp, at the rear of the muffler, that secures the tail pipe to the muffler.
4. Spray lubricant on the exhaust pipe behind the muffler.
5. Spray lubricant on all factory rubber isolators.
6. Remove the factory tail pipe hanger from rubber isolator.
7. Remove tail pipe from the rear of the vehicle.
8. Using the 15mm socket and ratchet, loosen the clamp that secures the intermediate pipe to the catalytic converter pipe.
9. Remove muffler hangers from rubber isolators.
10. Remove factory muffler assembly.
11. Install muffler hanger clamp (E) into rubber isolators near the rear of the factory muffler location.
12. Install intermediate pipe (A) and secure with exhaust clamp (F).
13. Insert muffler (B) into intermediate pipe (A). Place exhaust clamp with hanger (G) at the front of the muffler.
NOTE: Support the muffler temporarily, until the muffler hanger clamp is used.
14. Install tail pipe (C) through the rear of the vehicle.
15. Insert rear tail pipe hanger into rubber isolator at the rear of the vehicle, near the spare tire.
16. Insert tail pipe (C) through muffler hanger clamp (E) and into muffler (B).
17. Align tail pipe (C) properly and tighten muffler hanger clamp (E).
18. Install exhaust clamp (F) loosely over tail pipe (C). Do not tighten at this point.
19. Install exhaust tip (D) at the end of tail pipe (C).
20. Position exhaust clamp (F) over exhaust tip (D)
22. After installation, it is recommended that all clamps be re-tightened.
23. Tack weld all slip connections in three spots.
24. Lower the vehicle and reattach the negative battery cable.
NOTES:
1) It may be necessary to loosen and realign the spare tire for proper clearance.
2) All exhaust systems will expand about 1″ rearward when exhaust temperatures start to rise.
3) Use Anti-seize on threads of clamps.

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