Banks Power Ford Trucks: (Diesel ’99 - 03 7.3L Power Stroke) Power Systems- Big Hoss Bundles '99-03 F-250 & F-350 - Manual (Page 10)

muffler. Insert the hanger pin into the
rear rubber hanger.
30.
Slip the 5” Monster tailpipe
tip on. keep the wrapping on for
now. For a Fleet-side truck the 5”
tip should be hung 1” past the end
of the tailpipe. For a dually, the tip
should be 3
1 ⁄
2
” past the end of the tail
pipe. Snug up the clamp.
31.
Position all the exhaust
components such that all the hanger
pins are parallel with the frame pins
and all exhaust tubing is located
properly. Lightly tighten the clamps
to maintain position. The tailpipe tip
should be positioned 1-1
1 ⁄
2
“ below
the bottom edge of the fender. All
hangers should be hanging slightly
forward to allow for heat expansion
of the exhaust tubing (see Figure
8 ).
32.
With everything positioned
properly, begin to tighten the clamps
starting with the ones closest to the
turbo and working your way back.
Torque V-band clamp to 80 in-lbs.
Torque all remaining clamps to
35 ft-lbs.
33.
Remove protective wrapping
from tailpipe tip. The Monster
Exhaust installation is now complete.
Banks Techni-
Cooler
®
Installation
34.
To remove the factory
intercooler, it will be necessary to
remove the grille assembly. At the
front of the vehicle, remove the
pushpins holding the rubber air
deflector to the grille support and
remove the air deflector. Remove the
screws at the top of the grille, dis-
connect the lower clips with a small
screwdriver, and remove the grille.
35.
On each side, remove the
bulb from the headlight assembly.
Remove the two bolts below the turn
signal/marker light combination and
remove the assembly by pulling it
directly forward. Remove the bulbs
from the turn signal/marker lights
or disconnect the connectors to
separate it from the vehicle.
36.
Remove the pushpin and the
hood cable clip to disconnect the left
air deflector from the radiator core
support. Separate the left air deflector
from the grille support by removing
the pushpins from the bracket on the
grille support. Repeat this process for
the right side air-deflector, removing
the pushpins from the core support
and grille support.
37.
Remove the upper a/c
condenser brackets. Remove the
grille support bracket attaching bolts
and remove the grille support from
the vehicle. The a/c condenser needs
to be lifted at the same time as the
grille support is pulled away from the
vehicle. Pull from the bottom at first
to pivot the support upwards as you
pull forward. The a/c condenser will
fit between the air deflector brackets
as the support moves forward. Be
cautious of the corners of the front
fenders as the condenser is lifted
up. It may be beneficial to cover the
fender corners with masking tape or
some other form of protection.
38.
Scribe a line around the hood
latch with a sharp instrument to mark
the location of the latch, then remove
the latch from the upper radiator
support. do not remove the cable
from the latch. Move the latch out of
the way.
39.
Remove the jacking tools
from the core support and remove
the coolant reservoir bolt from the
jacking tool mount bracket. Remove
the upper radiator brackets. Remove
the upper diagonal brace bolts from
the upper radiator core support.
Remove the wiring harness from
the intercooler mounting studs and
Figure 8
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