Banks Power Ford Trucks: (Diesel ’94 - 97 7.3L Power Stroke) Power Systems- PowerPack, Stinger-Plus & Stinger '94-98 4" Exhaust - Manual (Page 5)

1.
replace the stock air filter
element with the Banks ram-air
filter.
2.
Remove the factory exhaust
by removing the clamp at the
catalytic converter outlet. remove
the Intermediate pipe, muffler
and tailpipe hanger pins from the
vehicle’s rubber hangers. remove
the intermediate pipe, muffler and
tailpipe assembly from the vehicle.
a heating torch maybe necessary to
remove the intermediate pipe slip
joint from the catalytic converter.
NOTE: Spray lubricant may assist in
hanger pin removal. Rubber hangers
can also be removed from the vehicle
to assist in tailpipe / muffler removal.
3.
remove the hardware on the
2-bolt flange retaining the catalytic
converter to the turbine outlet pipe.
remove the converter from the
vehicle.
NOTE: It is very important to inspect
the catalytic converter. Diesel
catalysts may become plugged with
soot and can cause a restriction to
exhaust flow. Performance may be
impeded if this is the case. Shine
a powerful flashlight into the slip
joint end of the converter. Observe
the light through the other end of
the converter. The full circle of the
flashlight should be visible without
any blockage in the grid work of
the catalyst. If excessive soot is
observed, the catalyst may need to
be cleaned. TAKE PRECAUTIONS to
avoid blowing soot toward the work
area or where it could be inhaled.
ALWAYS use breathing protection.
Also inspect the catalyst for damage
(i.e. chips, bent corners, etc.) to the
gridwork. If your catalytic converter
is damaged, it may be covered under
your vehicles emissions warranty.
4.
remove the decorative black
cover directly over the engine.
remove the engine-lifting hook at the
rear of the right cylinder head.
5.
AUTOMATIC TRANSMISSION ONLY
remove the transmission dipstick
and unbolt the dipstick tube and
engine ground wire from the rear of
the passenger-side cylinder head.
Pull the dipstick tube up out of the
transmission. Cover the dipstick tube
opening with a rag or paper towel to
prevent contaminants from entering
the transmission. for additional
clearance, remove the transmission-
fluid cooler line that runs to the
passenger-side of the transmission,
nearest the dipstick tube. Do not
start the vehicle while this line is
disconnected, as transmission fluid
will quickly pump out of the line.
6.
remove the V-clamp that secures
the factory turbine outlet pipe to the
turbocharger outlet. Pull the pipe up
as far as possible and cut the pipe
as close to the engine as possible.
Discard the top section then remove
the bottom portion of the pipe from
under the vehicle.
-EnD, SEcTIon 1-
Section 1
ExHAUST REMOvAL
BANKS
TAILPIPE
REAR HANGER
CLAMP
MONSTER
MUFFLER
4
"
SADDLE
CLAMP
3 1/2
"
SADDLE
CLAMP
FACTORY CATLYTIC
CONVERTER
Figure 1
96493 v.4.0
5