Banks Power Ford Trucks: (Diesel ’99 - 03 7.3L Power Stroke) Power Systems- Big Hoss Bundles '99-03 F-250 & F-350 User Manual
Page 11
remove the studs from the upper
radiator support. Remove the six
bolts on each end of the upper
radiator core support cross bar and
remove the upper core support
cross bar from the vehicle. It may be
necessary to pry the cross bar up out
of the slot in the core support.
40.
Pull the air conditioning
condenser up out of the lower
brackets and swing it up over the
engine and out of the way. Be careful
of the tubes that carry pressurized
refrigerant. do not bend the tubes
as they are aluminum, and can be
easily damaged. Using a bungee cord
or similar equipment, temporarily
suspend the condenser from the
hood of the vehicle, out of the way.
41.
Remove the bolt attaching the
power steering cooler to the diagonal
brace. Remove the diagonal braces
from the lower radiator core support.
Tilt the intercooler forward and
remove it up and out of the vehicle.
NOTE: Later models do not have
diagonal braces, unbolt power-
steering cooler from brackets as
required.
42.
Using the four
1
⁄
4
”-28 x 2” bolts,
washers and nylock nuts, loosely bolt
the new lower intercooler mounting
brackets to the lower mounting
crossbar. Position this mounting
assembly into the vehicle as shown
in Figure
5
. Using the lower diagonal
brace mounting holes as locations,
position the crossbar assembly level
in the vehicle and temporarily bolt
the brackets to the core support
using the lower diagonal brace bolts.
Using the brackets as a template,
mark the four holes necessary to
complete the attaching of the lower
mounting brackets, and drill four
1
⁄
8
” holes in those positions. Attach
the lower mounting brackets to
these holes in the core support with
the four #10 sheet metal screws
provided. Now remove the two
factory diagonal brace bolts.
NOTE: On later model vehicles
without diagonal braces and
associated bolt holes, slide the lower
intercooler mounting crossbar, with
brackets loosely attached, up the
sides of the core support opening
until the brackets come against
the bottom edges for the “ears”
that overlap the inside edge of the
core support opening. If the lower
intercooler mounting brackets
cannot be slid out far enough on
the crossbar to contact the sides
of the core support opening at this
elevation, slide each bracket outward
on the crossbar as far as it will go,
then tighten the
1
⁄
4
” thru-bolts, set the
crossbar assembly in the core support
opening, and level it to the vehicle.
With the crossbar assembly
positioned in the core support
opening as indicated, scribe the core
support through the four holes on
the inside edges of the brackets,
being certain that the front flanges of
the brackets (with the single unused
bolt hole) are against the face of the
core support. drill four
1
⁄
8
” holes at
the scribed locations, then attach the
brackets to the core support with four
#10 sheet metal screws provided.
43.
Remove the rubber air deflector
strips from the ends of the factory
intercooler by snipping the plastic ties
that run through the intercooler fins.
Attach the deflectors to the inboard
side of the 3-hole tabs on the Banks
intercooler by installing one
1
⁄
4
-28
x 1” hex bolt, washer, and nylock
nut assembly through the bottom
hole on the lower tab on each end
of the intercooler and the existing
bottom hole on each deflector strip.
The remaining three holes on the
deflector strips will not line up with
the holes in the intercooler. drill
or punch a new set of holes in the
deflector strips to line up with the
upper holes in the lower tabs on
the intercooler, then install a
1
⁄
4
-28 x
1” hex bolt, washer, and nylock nut
assembly in each of these locations.
(See Figure
5
) drill or punch a third
set of holes through each deflector
strip to line up with the middle hole
in the upper tabs on the intercooler.
44.
Loosely bolt the upper brackets
to the Banks Techni-cooler as shown
in Figure
5
using four
1
⁄
4
-28 x 1” hex
bolts,
1
⁄
4
washers and nylock nuts
through the outboard holes in the
two upper tabs on the intercooler.
45.
Trim the rubber air deflector
to clear the upper bracket attaching
nuts so the deflector will sit flat
against the tab on the intercooler.
Attach the deflectors to the
intercooler at the middle hole in each
upper tab using another pair of
1
⁄
4
”-28 bolt assemblies. Do not tighten
these bolts yet.
46.
On the passenger side of the
engine compartment, locate the air
conditioning filter/dryer assembly.
It will be necessary to modify the
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