Banks Power 2001-2007 (LB7, LLY & LBZ) Chevy_GMC 6.6L Duramax Turbo-Diesel Pickups - Manual (Page 4)

Exhaust System
Installation
1.
As a precaution, disconnect the
ground of the battery (if there is more
than one battery, disconnect both).
2.
Raise the vehicle and support it
with properly weight rated safety
stands, ramps or a commercial hoist.
Follow the manufacturer’s safety
precautions. Take care to balance the
vehicle to prevent it from slipping or
falling. When using ramps, be sure the
front wheels are centered squarely on
the topsides; place the transmission in
park; set the parking brake and place
blocks behind the rear wheels.
CAUTION: DO NOT WORK UNDER
ANY VEHICLE SUPPORTED ONLY
BY A JACK. SEVERE INJURY MAY
RESULT.
3.
Removal of the factory exhaust
can be simplified by cutting the factory
exhaust pipe behind the muffler. This
will allow the tailpipe to be removed
as a separate piece.
4.
For 2006-07 models, remove
the clamp located on the catalytic
converter outlet.
5.
For 2001-05 models, remove the
four (4) nuts from the factory exhaust
flange located at the back side of the
factory head pipe (retain for re-use).
6.
Remove the factory tailpipe from
the vehicle by disengaging the exhaust
system hanger pins from the rubber
hangers using a large screw-driver or
pry bar.
Note: Lubricating the rubber hangers
with WD-40 or similar lubricant will ease
removal of the hanger pins.
7.
Remove the factory muffler from
the vehicle by disengaging the hanger
pins from the rubber hangers using a
large screwdriver or pry bar.
NOTE: If Banks Headpipe (system 48670,
48671 or 48672) is being installed, perform
steps 8 thru 11 below. Otherwise
continue installation with step 12.
8.
On the front of the exhaust, spray
penetrating oil such as WD-40 on the
T-bolt of the factory v-band clamp to
prevent galling. Remove factory v-
band clamp and save for re-use.
9.
Remove factory head pipe from the
vehicle by disengaging the exhaust
system hanger pins from the rubber
grommets using a large screwdriver or
pry bar.
10.
Install Banks head pipe in vehicle
and insert the hanger pin in the rubber
exhaust grommet.
NOTE: Be sure to install the hanger pin
in the same location as the previously
removed factory head pipe.
11.
Loosely install the v-band clamp
on head pipe flange and only tighten
the T-bolt on the clamp to the point
that the pipe is snug but can still be
rotated in the clamp for adjustment/
alignment.
NOTE: Do not completely tighten the
V-band clamp at this point.
NOTE: proceed to step 14 for 2006-07
models installation instructions
CAUTION: The following step
involves cutting a stainless steel
tube. Safety glasses should be
worn during any cutting operation
and care should be taken to avoid
injury due to sharp edges and
burrs.
12.
For Extended Cab Long Bed and
Extended Cab Short Bed models only:
cut the Banks Flanged intermediate
pipe (53717) based on the following
configurations. See Table 1. cut the
Non-flanged end of the intermediate
pipe. See Figure 2.
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96408 v.9.0