Banks Power Dodge Trucks: (Diesel ’94 - 98 5.9L Cummins) Power Systems- PowerPack, Stinger-Plus & Stinger systems - Manual (Page 5)

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CaUTIoN! make sure rags are removed from exhaust
manifold prior to reinstalling turbine housing!
16.
Install the probe in the manifold. anti-seize
on the threads is recommended.
for Stinger only, follow steps 17-20 then proceed to
step 25. for Stinger-plus and powerpack installations,
proceed to step 21.
17.
Remove the E-clip from the wastegate arm,
allowing the actuator rod to be released.
Save the E-clip for reuse. Unbolt the three
actuator bracket bolts from the turbine housing.
Note the location of all five spacers and retain the
spacers and bolts for reassembly. Remove the two
nuts holding the actuator to the bracket and remove
the actuator. Loosen the jam nut on the actuator rod
and remove the rod end link and the jam nut from
the factory actuator. See figure 4.
18.
Thread the jam nut and rod end link onto
the banks actuator. Install the actuator
onto the bracket using the original nuts. Loosely
fasten the actuator assembly to the turbine
housing using the original spacers and bolts in
their original configuration. Do not slip the rod end
link onto the wastegate arm yet.
19.
Turn the rod end link on the threads of the
actuator rod until the hole lines up with the
pin on the wastegate arm. Turn the rod end
clockwise an additional 6 full turns, such that it
will add preload to the wastegate.
20.
Loosen the bracket bolts and slide the rod end
link over the wastegate arm. Retighten the
bracket bolts. Replace the E-clip and tighten the jam
nut against the rod end link.
for Stinger installation proceed to step 25.
TURboCHaRGER DISaSSEmbLy aND REaSSEmbLy:
Clamp the turbine inlet flange of the
turbocharger in a bench vise. Loosen the
four bolts, attaching the turbine housing to the
center bearing section of the turbocharger. (See
figure 3)
Remove the bolts, lockplates, and clamp
plates. Carefully remove the center bearing
and compressor assembly from the cast iron
turbine housing. If the turbocharger has been in
service for some time, rust and carbon may prevent
the center bearing and compressor assembly from
easily separating from the turbine housing. If light
hammer blows, penetrating oil or heat will not
free the compressor assembly from the turbine
housing, the clamp bolt adjacent to the turbo oil
inlet connection may be backed out so as to push
against the bearing casting and separate the two
components. Remove any loose rust or carbon
from the bearing housing that might prevent proper
engagement into the new turbine housing.
Install the center bearing and compressor
assembly into the new turbine housing
supplied. apply a dab of anti-seize compound to the
bolts, then install bolts, clamp plates, and lock plates
finger tight to allow for final positioning.
Remove the exhaust outlet adapter from
the rear of the turbine housing and save for
reuse. Clamp the exhaust inlet flange of the new
turbine housing in a bench vise. Install the turbo
exhaust outlet adapter casting to the turbine
housing with five 8mm x 20mm metric hex bolts.
apply a dab of anti-seize compound to the bolts,
then torque the bolts to 11.3N-m (100 in-lbs.).
make sure the turbine inlet flange does not rotate
in the vise while torquing. (See figure 4)
TURBOCHARGER INSTALLATION
Install a new turbo exhaust inlet gasket
provided and apply a dab of anti-seize
compound to the four turbo mounting studs.
for Stinger installations, reuse the stock gasket.
Install the turbocharger on the exhaust manifold.
Tighten the turbocharger mounting nuts to
32N-m (24 ft.lbs.) torque.
25.
24.
23.
22.
21.
figure 3
p.N. 96384 V.3.0