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1. Turn off the power at the main panel. Pull down the grille cover and remove it. Then unscrew or pry out the old fan motor assembly using a screwdriver.
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2. Remove the electrical cover plate. Carefully slide out the wires and remove the wire connectors. Turn on the fan switch (on the wall) and test the wires with a voltage tester to make sure the power is off. Untwist the wires. Remove the lock nut from the cable.
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3. Go into the attic and unscrew the old fan housing from the joist. Remove the cable and pull out the wiring. Untape or remove the clamps that hold the ductwork at the housing and at the roof.
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4. Trace the new fan housing outline on the ceiling over the old opening. Enlarge the hole with a drywall saw. Pay attention to ceiling joist locations.
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5. Align the fan housing from above, making sure the housing is oriented properly for ductwork and electrical connections. Then screw the mounting brackets that hold the fan to each joist with 1-in. drywall screws.
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6. Screw the 4-in. aluminum elbow to the fan’s exhaust port using three 3/8-in. self-tapping Phillips sheet metal screws. Take care not to hamper the damper flap inside. Then slide out the inner liner of the flexible ductwork, gather three or four of the metal rings and use three more screws to attach the liner to the elbow.
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7. Pull down the insulation jacket and tighten the 6-in. metal clamp at the elbow. Cut the duct to length with a utility knife and wire cutters and attach a 6-in. piece of straight aluminum pipe to the end with screws and a clamp, leaving about 3 in. of metal exposed. Using metal snips, cut the 3-in. exposed end of the aluminum pipe at an angle to match the roof pitch.
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8. Remove the plate at the electrical splice box and pull out the fan wires. Push the electrical cable through the hole provided and anchor it with a cable clamp. Twist together the electrical wires (white to white and red or black to black) and install the connectors. Attach the bare copper wire to a ground clip or a screw on the plate. Fold the wires back into the electrical box on the housing and replace the cover.
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9. Caulk the ceiling/housing joint with silicone or another high-quality caulk.
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10. Pry up surrounding nails with a pry bar and pull off the old roof vent cap. Cut back the shingles and felt paper with a utility knife, leaving about 3/4 in. of sheathing exposed around the existing hole. Lay the piece of aluminum ductwork over the hole as a template. Trace around the template with a pencil or marker. Using a jigsaw, cut a new oval hole in the roof to fit the duct.
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11. Reach into the roof hole and pull up the angled end of straight duct, leaving about 3/4 in. above the roof surface. Screw it to the sheathing with 1/2-in. self-tapping sheet metal screws. Seal the gap between the duct and the shingles with silicone caulk or another high-quality caulk.
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12. Slide the new vent cap under the shingles for a proper fit. Pull it out. Apply roofing cement to the shingles where the top and side flanges will rest. Nail in place.
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13. Gently lift the shingles and nail the vent cap at the top and sides using roofing nails. Apply roofing cement under the shingles at the sides and the top of the vent cap and over nails.
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