Banks Power Dodge Trucks: (Diesel ’03 - 07 5.9L Cummins) Power Systems- Stinger system '03-04 - Manual (Page 2)

General Installation
Practices
1.
For ease of installation of your
Banks Stinger, familiarize yourself
with the procedures by reading the
entire manual before starting work.
This instruction manual contains
24
pages of text, illustrations and parts
listing.
2.
Disconnect the ground cable
from the battery before beginning
work. If there are two batteries,
disconnect both.
3.
Route and tie wires and hoses
a minimum of 6 inches away from
exhaust heat, moving parts and sharp
edges. clearance of 8 inches or more
is recommended where possible.
4.
When raising the vehicle, support
it on 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; put the
transmission in park; set the hand
brake; and place blocks behind the
rear wheels.
Caution! Do not use floor
jacks to support the vehicle
while working under it. Do
not raise the vehicle onto
concrete blocks, masonry
or any other item not
intended specifically for
this use.
5.
The installation should be
performed at a time when the vehicle
has been allowed to completely cool.
This installation requires the installer
to work near surfaces that may
remain hot after the vehicle has been
run. Failure to allow the vehicle to
cool may result in personal injury.
6.
During installation, keep your
work area and components clean
to avoid possible dirt entry into the
engine.
7.
Save this Owner’s Manual as a
reference for system maintenance
and service.
Notification
The Banks Ram-Air Filter comes pre-
oiled and no oiling is necessary for
initial installation. Service the filter as
specified in the cleaning and Oiling
the Banks Ram-Air Filter Section of
this manual.
Tools Required:
These tools are necessary for all
levels of installation unless otherwise
specified.
•
1 ⁄
4
” and 3 ⁄
8
” drive ratchets with inch
and metric sockets including 5 ⁄
16
”,
7 ⁄
16
” deep 1 ⁄
4
” drive sockets and a 1 ⁄
4
”
drive extension
• Inch and metric combination or
open-end wrenches
• Standard and Phillips head
screwdrivers
• Standard and needle-nose pliers
• Pocket or X-Acto knife
• Clean shop towels or rags
• Drill motor
• Tap handle
•
1 ⁄
8
” Allen wrench
• 3 ⁄
16
” and 7 ⁄
16
” drill bits
• 1 ⁄
4
” NPT tap
• Heat gun (suggested) or cigarette
lighter
• Pry bar or large groove-joint (water
pump) pliers
• Wire crimping/stripping tool
• Oxy-acetylene torch or
reciprocating saw
Highly recommended tools
and supplies:
• Inch-pound and foot-pound torque
wrenches
• Compressed air source and hose
• Air pressure regulator
• Rubber tipped air blowgun
• Multimeter or 12-volt test light
• Penetrating oil or light lubricant
spray
• 90-degree motor drill
Dear Customer,
If you have any questions
concerning the installation
of your Banks Power
system, please call our
Technical Service Hotline
at (888) 839-2700 between
7:00 am and 5:00 pm (PT).
If you have any questions
relating to shipping or
billing, please contact
our Customer Service
Department at
(888) 839-5600.
Thank you.
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