Borla 140897 Ford Bronco Cat Back Exhaust System Installation Guide

Borla 140897 Ford Bronco Cat Back Exhaust System

Product Information

The Borla Performance Industries is a leading manufacturer of high-performance exhaust systems. The product in question is the Borla Performance Cat-Back Exhaust System designed specifically for the Ford Bronco Climber. The system is available in different part numbers: 140897, 140898, 140901, 140902, and 60725. It is manufactured by Borla Performance Industries located at 500 Borla Drive, Johnson City, TN, 37604-7523. For any inquiries, you can contact them at 805-986-8600 or visit their website at www.BORLA.com.

Product Usage Instructions

Before starting the installation process, ensure that all the parts mentioned in the bill of materials provided are present in the box. It is essential to read and understand the installation instructions completely before proceeding.

Tools Required:

• 3/8 drive ratchet
• 3/8 drive extension
• 13mm deep well socket15mm deep well socket
• Pry bar

Shop Supplies Required:

• Spray lubricant

Installation Steps

Original Exhaust System Removal:

1. Lubricate all hangers, rubber isolators, bolts, and nuts.
2. Loosen the clamp attaching the muffler assembly to the vehicle.
3. Using a muffler stand or an additional person, remove the rear muffler assembly hangers from the two rubber isolators and take out the rear muffler assembly from the vehicle.
4. Optionally, remove the original rubber isolator from the original hanger.
5. Using a flathead screwdriver or pry bar, remove the front pipe assembly hanger from its rubber isolator.
6. Remove the hardware that connects the front pipe assembly to the flange on the vehicle and the hardware that connects the rubber isolator to the vehicle. These hardware pieces will be reused during the installation of the Borla system.
7. Remove the front pipe assembly from the vehicle by lowering the flange end away from the vehicle and moving it toward the front of the vehicle. Also, remove the rubber isolator for later reuse.
8. The original exhaust system has been successfully removed.

Borla Performance Cat-Back Exhaust System Installation:

1. Orient the components on the shop floor according to the Borla bill of materials drawing on pages 2-3.
2. Install the original rubber isolator onto the hanger of the Front Pipe Assembly.

Installation Guide for Ford Bronco
PNs: 140897, 140898, 140901, 140902, 60725

Please compare the parts in the box with the bill of materials provided to ensure that you have all the parts necessary for this installation. These instructions have been written to help you with the installation of your Borla Performance exhaust system. Please read this document completely before beginning the installation of your system.

To ensure this part number fits your specific model year, please visit our website for the latest model year listings at www.BORLA.com

Thank you for purchasing a Borla Performance Cat-Back™ exhaust system.

• Borla Performance Cat-Back™ exhaust system PNs 140897, and 140898 are designed for the Ford Bronco, equipped with a 2.3L inline-4 turbo-charged engine and 4WD automatic or manual transmission.
• Borla Performance Cat-Back™ exhaust system PNs 140901, and 140902 are designed for the Ford Bronco, equipped with a 2.7L V6 twin turbo-charged engine and 4WD automatic transmission.
• Borla Performance’s additional muffler PN 60725 is designed to work on PNs 140897, 140898, and 140902 to modify the desired sound level.
• Borla Performance Industries recommends that an exhaust shop or professional after-market parts installer, who has all the necessary equipment, tools and experienced personnel needed for proper installation, should install this system.

However, if you decide to perform the installation, we recommend someone should help you. Ensure the installer uses all under-car safety precautions including eye protection.

Please take time to read and understand the following…
By installing your Borla Performance exhaust system, you indicate that you have read this document and you agree with the terms stated below. It is the responsibility of the purchaser to follow all installation instruction guidelines and safety procedures supplied with your Borla Performance exhaust system. Borla Performance Industries assumes no responsibility for damages occurring from misuse, abuse, improper installation, improper operation, lack of responsible care, or all previously stated reasons resulting from incompatibility with other manufacturer’s products and/or systems. Included with your Borla Performance exhaust system is a warranty card. Please read it carefully before you begin any work on your vehicle. If you should have any questions regarding our warranty policy, installation, or any other matter about your new Borla Performance exhaust system, please give us a call at the number provided on the warranty card.

Minimum Required Tool List

TOOLS:

• 1. 3/8” drive ratchet
• 2. 3/8” drive extension 6”
• 3. 13mm deep well socket
• 4. 15mm deep well socket
• 5. Pry bar

SHOP SUPPLIES:

1. Spray lubricant

Borla Performance Bill of Materials

Caution!!! Never work on a hot exhaust system. Serious injury in the form of burns can result If the vehicle has been in use and the exhaust system is hot, allow the vehicle to cool for at least 1 hour. Always wear eye protection when working under any vehicle.

Note : We recommend that you use a hoist or hydraulic lift to facilitate the installation of your new Borla Performance Exhaust System. Taking all under-car safety precautions, lift the vehicle using a hoist or hydraulic lift. Once this has been done, you may begin the removal of your old exhaust system from your vehicle.

Note : Before removing the original exhaust system from your vehicle, please compare the parts you have received with the bill of materials provided on the previous page toensuree that you have all the parts necessary for the installation of your new Borla Performance Exhaust System.

Note : With a used vehicle, we suggest a penetrating spray lubricant to be applied liberally to all exhaust fasteners allowing a significant period for the chemical to lubricate the threads before attempting to disassemble.

Original Exhaust System Removal

1. Lubricate all hangers, rubber isolators, bolts and nuts.
2. Loosen clamp attaching muffler assembly to the vehicle (Fig. 1).
3. Using a muffler stand or an additional person, remove the rear muffler assembly hangers from the two rubber isolators and remove the rear muffler assembly from the vehicle (Figs. 2-3).
4. Optional : Remove the original rubber isolator from the original hanger so that you can’t see it hanging (Fig. 4).
5. Using a flathead screwdriver or a prybar, remove the front pipe assembly hanger from its rubber isolator (Fig. 5).
6. Remove the hardware that connects the front pipe assembly to the flange on the vehicle and remove the hardware that connects the rubber isolator to the vehicle (Fig. 6). This hardware will be reused on the installation of your Borla system.
7. Remove the front pipe assembly from the vehicle by lowering the flange end away from the vehicle and moving it toward the front of the vehicle (Fig. 7). Remove the rubber isolator to be reused on your Borla system.
8. The original exhaust system was removed.

Borla Performance Cat-Back

Exhaust System Installation

1. Orient components on the shop floor according to Borla’s bill of materials drawing on pages 2-3.
2. Install the original rubber isolator onto the hanger of the Front Pipe Assembly (Fig. 8).
3. Install the Front Pipe Assembly by mating the flange to the vehicle. Loosely tighten the hardware on the flange and the hardware connecting the rubber isolator to the vehicle (Fig. 9).
4. Place a clamp over the expanded end of the Muffler Assembly and insert the inlet into the Front Pipe Assembly (Fig. 10). Do not tighten the clamp.
5. If installing on a 2-door, skip to step 6. Place a clamp over the expanded end of the Extension Pipe and insert the inlet into the Muffler Assembly (Fig. 11). Do not tighten the clamp.
6. Place a clamp over the front expanded end of the Over-Axle Pipe Assembly and insert the inlet into the Extension Pipe (4-Door) or Muffler Assembly (2-Door). Insert the hanger into the original rubber isolator (Figs. 12-13). Do not tighten the clamp.
7. Place a clamp over the rear expanded end of the Over-Axle Pipe Assembly and insert either the Turndown or Muffler Assembly (depending on your system). For the Muffler Assembly, insert the hanger into the original rubber isolator (Fig. 14). Do not tighten the clamp.
8. Once the position has been determined to be correct, tighten the hardware on the Front Pipe Assembly and then tighten the Accuseal clamps to 32-35 ft. lbs.
9. Before starting your vehicle, make sure to check all wires, hoses, brake lines, body parts and tires for safe clearance from the exhaust system.
10. Start the vehicle and check for any leaks. If any leaks are found, determine the cause (such as a loose or incorrectly positioned clamp) and repair as necessary-

WARNING : Use extreme caution during installation. Torque all fasteners according to the manufacturer’s torque values and tightening sequence. DO NOT use air impact tools to tighten fasteners on Borla Performance Exhaust Systems. Use of such tools may result in bent flanges or gasket contact areas leading to exhaust leaks.

NOTE : When you first start your vehicle after the installation of your new Borla Performance Exhaust System, there may be some smoke and fumes coming from the system. This is a protective oil-based coating used in the manufacturing of mandrel-bent performance exhaust tubing. This is not a problem and will disappear within a very short period after the exhaust has reached normal operating temperatures.

DOCUMENT ID
A-36063 Rev. A

BORLA PERFORMANCE INDUSTRIES
500 Borla Drive Johnson City TN, 37604-7523 805-986-8600

References

• Borla® - Performance Exhaust Systems, Mufflers & Induction

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