Banks Power Ford Trucks: (Diesel ’99 - 03 7.3L Power Stroke) Power Systems- Big Hoss Bundles '99-03 F-250 & F-350 - Manual (Page 14)

the sensor. Install the 1 ⁄
8
” hose by 1 ⁄
8
”
NPT tee fitting and the spring band
clamps, provided, between the cut
ends of the hose as shown in
Figure
5 .
71.
Install one 1 ⁄
8
” NPT female by
1 ⁄
8
” compression 90° fitting onto the
threaded end of the tee. Sparingly
apply pipe sealant tape or paste on
the male pipe threads, and adjust the
90° fitting to point back toward the
firewall, as shown in Figure
9 .
do not allow any sealant to cover the
small hole in the fitting. do not over-
tighten the plastic fitting.
72.
Install one end of the 1 ⁄
8
”
diameter plastic tube provided into
the compression fitting on the plastic
tee or the fitting on the compressor
discharge elbow and tighten the nut.
Be sure the plastic tube cannot be
pulled out of the ferrule, but do not
over-tighten the nut.
73.
Route the free end of the tube
up and along the top of the firewall
toward the brake master cylinder
assembly. Use caution to avoid kinks
in the line. Tie the tube to existing
wires and hoses with the cable ties
provided. Follow the routing of the
pyrometer lead-wire through the
firewall.
74.
Route the plastic tube to the
gauge panel and cut the tube to
the proper length. Install the gauge
through the panel or console using
the U-clamp and two hex nuts
provided with the gauge.
75.
Install the 90° elbow fitting onto
the connection at the back of the
gauge. Use Teflon thread sealer on
the male threads of the gauge nipple.
do not allow any sealant to cover
the pin-sized hole in the end of the
gauge nipple.
76.
Insert the tube into the nut and
ferrule on the adapter fitting at the
gauge, then tighten the nut against
the tube and ferrule. do not over-
tighten.
77.
connect the 4-pin connector
of each gauge into the back of its
corresponding gauge.
a. crimp the remaining Black and
REd wires from each 4-pin
connector gauge harness to the
butt connectors as shown in Figure
10.
b. Strip one end of the REd wire
and crimp it to the butt connector
containing the REd wires from step
‘a’.
c. Strip one end of the BLAck wire
and crimp it to the butt connector
containing the BLAck wires from
step ‘a’.
d. Route the RED wire to the fuse box.
Locate the appropriate fuse for
instrument lighting in the owner’s
manual. cut the REd wire as
required and strip the end. crimp
the push on connector to the REd
wire and connect to the fuse as
shown in Figure 10. Alternatively,
locate power wire to dimmer
switch and install T-tap. cut the
REd wire as required and strip
the end. crimp the push on T-tap
connector to the REd wire and
connect to T-tap on dimmer power
wire.
e. Locate a metal surface that will
serve as an acceptable chassis
ground. cut the BLAck wire to a
sufficient length that will allow it to
reach the chassis ground and strip
the end. crimp the ring terminal to
the BLAck wire as shown in Figure
10.
f. drill a 1⁄8” hole, if required, to
attach the ring terminal to the
chassis ground. Caution: If drilling,
check the backside to make sure
there are no components that may
be damaged by drilling.
g. Use the supplied self-tapping screw
to secure the ring terminal to the
chassis ground.
NOTE: On vehicles with an
automatic transmission, complete
the TransCommand installation
before proceeding.
Banks Big Hoss
module Installation
78.
Be certain battery ground cables
have been disconnected.
79.
Locate the engine control unit
(EcU) under the dash toward the
left-hand side of the vehicle. It will be
housed in a black plastic box bolted
to the side of the vehicle. Loosen
the bolt attaching the electrical
connector to the EcU on the engine
compartment side. This will be the
connector closest to the left front
fender. See Figure
11 .
80.
Loosen the two 7mm hex bolts
on the rear portion of the black
plastic box. Remove the box and ECU
from the vehicle together. Pull the
ECU out of the plastic box.
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