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 12
clamping bracket to allow clearance
for the new tube assembly. Remove
the upper filter dryer bracket by
unbolting in three places. Using a
hacksaw or other cutting tool cut the
forward half of the clamp off in front
of the elevated tab across from the
opening of the clamp. Next cut the
remaining tab off of the open side of
the clamp. Reinstall the bracket using
a #56 hose clamp provided to secure
the filter/dryer unit to the bracket.
47.
Slide three #52 hose clamps
over the left boost tube. These will
be used later to secure the heatshield
in place. Set both boost tubes into
place in the vehicle. Place two of
the 3” silicone hump hoses onto
the intercooler inlet and outlet,
and fasten with the T-bolt clamps
provided. Position two more clamps
on the open ends of the silicone
hoses, and place the intercooler into
the vehicle slipping the boost tubes
into the hoses on the intercooler and
the intercooler into the rubber saddles
on the lower mounting brackets. do
not tighten these clamps yet.
48.
Place the air conditioning
condenser back into its original
position. Reinstall upper crossbar
into truck, using the original bolts.
Reinstall the diagonal braces to the
radiator support and reattach the
power steering cooler to the right
side diagonal. Note: Rotate the upper
power-steering fluid tube in the clip
to allow the hose portion to clear the
bottom of the right lower intercooler
bracket.
49.
Remove the factory rubber
isolators from the factory intercooler
and install them into the upper
brackets of the Banks intercooler.
Install the original studs through the
isolators into the upper crossbar
and tighten them. Tighten the upper
mounting-bracket bolts on the
intercooler. For late 1999
1
⁄
2
–2002
models proceed to Step
55
.
50.
Remove the sensors from the
factory compressor discharge plenum
casting and install them into the
Banks TwinRam intake assembly.
Early 1999
1
⁄
2
models: Remove the
heating element from the factory
compressor discharge plenum casting
and install it in the Banks TwinRam
intake assembly.
51.
Slide the two 2” silicone hoses
up the legs of the TwinRam. Slip two
#36 hose clamps over each hose and
install the TwinRam to the engine,
sliding the hoses down the legs and
onto the intake stubs, making sure
that the hoses are positioned equally
between the TwinRam legs and the
manifold stubs. Tighten the clamps.
Attach the bracket to the rocker cover
using the 8mm x 30mm metric bolts
and spacers provided.
52.
Attach the wastegate control
solenoid to the tab on the TwinRam
with the supplied
1
⁄
4
-20 x 1
1
⁄
14
” hex
bolt and washer. Reconnect the
wiring harnesses to the sensors.
53.
Attach the right side boost tube
to the TwinRam using a 3” silicone
hump hose, and two T-bolt clamps.
54.
Place the new O-ring into the
recess in the compressor housing
and attach the compressor discharge
elbow to the compressor housing
with the new V-band clamp provided.
A small amount of bearing grease
may be used to hold the O-ring in
position while installing the elbow.
Bolt the compressor discharge
elbow to the TwinRam through the
tab provided for this purpose using
the
5
⁄
16
” bolt, washers, and nylock
nut provided. Install a
1
⁄
8
” NPT x
1
⁄
8
”
compression fitting (supplied in the
boost gauge kit) in the bung on
the compressor discharge elbow.
Sparingly apply pipe sealant tape or
paste on the male pipe threads, and
tighten the hex on the fitting body
(NOT the compression nut). Proceed
to Step
56
.
55.
Late 1999
1
⁄
2
–2002 models:
Place the O-ring into the recess in
the turbo compressor outlet and
reinstall the factory compressor
discharge plenum casting on the
turbocharger. A small amount of
bearing grease may be used to hold
the O-ring in position while installing
the casting. Slide the hump hoses on
the boost tubes onto the compressor
plenum discharge casting. Reconnect
any wiring or sensor tubes to
components on the compressor
discharge casting. Reconnect boost
line to wastegate actuator.
56.
While engine is running, check
for oil leaks around the base of the
turbocharger center section or the
pedestal mount. Repair any leaks
before continuing. NOTE: The most
likely cause of an oil leak in this
installation is a pinched O-ring at the
base of the turbocharger.
57.
Make sure that the boost tubes
clear all moving parts, and that the
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