Banks Power Dodge Trucks: (Diesel ’94 - 98 5.9L Cummins) Power Systems- PowerPack, Stinger-Plus & Stinger systems - Manual (Page 3)

p.N. 96384 V.3.0 3
for quick-Turbo installation only, proceed to step 5.
for Twin-Ram manifold installation only, proceed to
step 43.
1.
Unbolt front and rear muffler U-clamps and
rear tailpipe hanger, then remove muffler
and tailpipe from vehicle. Heat slip joints at
muffler inlet and outlet to a red-orange color to
allow separation of the components. Lubricate
rubber hangers with wD40 or a similar product to
allow hanger rods to be pried out with a large
groove-joint pliers. Save tailpipe hanger hardware
and front muffler hanger clamp assembly.
Note: If vehicle is to be raised on a hoist, use
care not to bend clamps and brackets around
rear axle housing where lifting points of hoist
contact housing. Clamps may be loosened and
repositioned to clear hoist prior to lifting.
2.
Install banks Dynaflow™ muffler on
catalytic converter outlet tube. Note that
alignment notch on muffler inlet indexes with a
tab on the top of the catalytic converter outlet
tube. Install the dual pin supplied rear hanger
clamp onto the muffler outlet. Install rear muffler
hanger rods in factory rubber hangers. Install front
muffler hanger clamp around muffler inlet and
into rubber hanger, then tighten clamp while
pushing muffler forward against locator tab on
catalytic converter. See figure 1.
3.
Install tailpipe in muffler outlet and attach
tab on tailpipe to factory rear hanger using
original hardware. on 1998 models, install the
tailpipe hanger pins into the factory rubber
hangers. Install new 3 1 ⁄
2
-inch U-clamp at muffler
outlet and tighten once tailpipe has been adjusted
for final position.
Reposition and tighten any components that were
loosened on the rear axle to clear hoist lifting
points.
4.
Remove air filter cover and replace filter
element with banks Ram-air™ reusable air
filter element. See cleaning instructions at end of
this booklet.
TURBOCHARGER REMOVAL
position vehicle on a hoist. If no hoist is
available, position vehicle on a flat level
surface.
Disconnect the air inlet tube from the air
cleaner and the inlet to the turbocharger.
Disconnect the exhaust pipe from the rear of the
turbocharger.
Remove the two oil drain tube bolts from
the turbocharger.
7.
6.
5.
INSTaLLaTIoN pRoCEDURE
fIGURE 1