Banks Power Ford Trucks: (Gas ’99 - 11 6.8L V10; 6.2L V8) Power Systems- PowerPack & Stinger '99-04 F250_F350 6.8L V10 (Pickups & Excursions) - Manual (Page 7)

CAUTION: Make sure that the
heatshield does not come in
contact with the positive terminal
of the starter once the heatshield is
tightened down.
10.
Inspect the exhaust mounting
surfaces of the cylinder heads
and clean away any deposits to
assure proper sealing of the Banks
TorqueTubes. Be careful when doing
this as the cylinder heads are made
from aluminum, and can be easily
damaged. we recommend the use of a
scotchbrite ® pad.
Note: On 2004 models, you will need
to remove the rubber flap surrounding
the passenger side motor mount.
Using scissors, slit the flap and remove
it from the motor mount.
11.
Place a small amount of anti-
seize on the threads of each of the
supplied manifold bolts. use the new
gaskets provided when installing
the TorqueTubes. lift the Banks
TorqueTube manifolds into place and
install one or two bolts to hold them in
position. See Figure 1.
12.
make sure the o-ring is on the
dipstick tube, and reinstall it into the
hole in the engine block. reattach the
dipstick tube bracket to the cylinder
head with the original bolt.
13.
If the vehicle has EGR, attach the
eGr tube to the fitting in the Banks
TorqueTube manifold. If necessary,
loosen the fitting at the top of the eGr
tube to allow the tube to be positioned
properly.
14.
install the remaining bolts into
the heads and torque to 18 ft-lbs. use
care to ensure that the threads of the
bolts do not cross thread in the alum-
inum threads of the cylinder heads.
15.
if additional clearance is needed
between the front tube of the left
manifold and the power steering
line, loosing the fitting on the power
steering box and rotate the hose
until at least 3 inches of clearance
exists. Retighten the fitting. Install the
supplied heat shield blanket over the
hose and wire tie the hose away from
the manifold.
For vehicle models earlier than
2000, proceed to step 19.
16.
On 2000 and later vehicles,
remove the factory muffler and tailpipe
from the catalytic converter and
intermediate pipe. start from the rear
of the rubber hangers, then remove
the muffler and tailpipe. heat the slip
joints with a torch to allow them to
separate, or cut through the piping.
Do not cut or damage the catalytic
converter outlet or intermediate pipe.
once the muffler and tailpipe have
been removed, remove the catalytic
converter from the vehicle. save all
hardware and hangers, as some may
be reused.
Note: If you are not sure of the model
year of your vehicle, check for the
location of the 3-bolt converter inlet
flange. If the flange is in front of the
transmission crossmember, your
vehicle is 2000 or later.
17.
measure and mark a point 8”
back from the rear of the catalytic
converter inlet flange on the top
side of the catalytic converter inlet
pipe. cut through the pipe at this
point square to the pipe centerline
to remove the converter inlet flange
leaving a section of the pipe and the
hanger on the converter. See Figure 3.
Deburr the cut pipe on the converter,
then proceed to step 20.
18.
slip a 3” u-clamp over the outlet
end of the Y-pipe, then slip the Y-pipe
onto the cut inlet stub on the catalytic
converter, but do not tighten the
clamp. Position the catalytic converter
and y-pipe assembly in the vehicle
96395 v.6.0
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