INSTALLATION INSTRUCTIONS
** Installation recommendation: JBA recommends in most case that the vehicle be taken to a reputable exhaust shop for installation.
40-9016
2005-2007 Toyota Tacoma 4.0L V6
Parts List: Recommended Tools:
A. Head pipe 1 9/16’’ Deep wall socket
B. Muffler 1 12mm socket
C. Tail pipe w/ hanger & tip 1 Channel lock pliers
D. 2.5” clamp w/ hanger 1 14mm socket
E. 2.5” clamp 1 Hack saw or reciprocating saw
F. 2.5” clamp w/ hanger 1 12mm socket
3/8’’ drive ratchet
Channel lock pliers
anti seize
Spray lube
rubber mallet
A
B
C
D E
F
TO START:
1. Remove and inventory new JBA
exhaust.
2. Disconnect negative battery cable
and allow vehicle exhaust to cool.
3. Spray lube on rear tail pipe hanger
rod, and remove from rubber grommet
using channel lock pliers.
4. With muffler properly supported,
remove two flange bolts in front of
muffler assembly using a 14mm
socket. Save bolt’
s they will be reused.
5. Spray lube on two rear muffler
hanger rods, and remove from lower
holes in rubber grommets using
channel lock pliers.
6. Remove muffler assembly, taking
care not to damage flange gasket.
8. Bolt JBA head pipe (A) to flange
using 14mm socket.
9. Slip 2 1/2” clamp with hanger (D)
onto head pipe (A) and
fit hanger
into lower hole on rubber isolator.
10. Install muffler (B) with offset end
forward and down. Slip on 2
’’.
11. Support muffler and align straight
up and down. Install 2 1/2
’’ clamp
(D) over front muffler slip joint and
tighten completely using a 9/16
’’
deep wall socket. NOTE: Use anti
seize on threads of clamps for
stainless steel systems.
13. Install tail pipe into rear muffler
slip joint.
14. Install and position rear muffler
2 1/2’
’ clamp with hanger (F) over
slip joint and insert rods into lower
holes in rubber grommets. Tighten
completely using a 9/16’’ deep socket.
NOTE: Use anti seize on threads of
clamps on stainless steel system.
15. Check exhaust kit for proper
clearance, and location of tip.
16. After installation, it is
recommended
that all clamps be retightened.
17. Tack weld all slip connections in
three spots.
18. Using a soft cloth, remove all
prints from turnout tip (D).
19. Lower vehicle and reattach the
negative battery cable.
NOTES:
1. If anti seize is not used on threads
of clamps before tightening, the nuts
will gall and clamp will break.
Other products also available:
Get even more power for your Tacoma
with a set of 50 state smog legal JBA
Cat4ward® headers. These are match
tuned for maximum performance with
your new exhaust. With large diameter
primary tubes, thick flanges, and JBA’s
dyno proven design, these headers
will give you a signifacant increase in
torque and horsepower to compliment
your new JBA exhaust system.
Part No. Application
2035S 05 Tacoma 4.0L V6
Stainless steel
JBA Equipped - 2005 Tacoma X-runner
4.0L V6 5spd
12. Install tail pipe (C) from rear of
vehicle, and slip rear tail pipe hanger
rod into lower hole in rubber
grommet.
in place on factory assembly and install
new head pipe (A).
7. Make sure flange gasket is properly
JBA recommends taking the vehicle to a muffler shop and having all slip connections tack welded. 7.5.05
(1 pages)
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