Banks Power Ford Trucks: (Diesel ’99 - 03 7.3L Power Stroke) Power Systems- Big Hoss Bundles '99-03 F-250 & F-350 - Manual (Page 3)

1.
Replace the factory air filter
element with the Banks Ram-Air™
filter.
2.
Raise the vehicle on a hoist or
safety stands to provide access to the
exhaust system. Loosen the clamp at
the front of the muffler and pry the
muffler and tailpipe hanger pins from
the rubber hangers (spray lubricant
will ease hanger removal). Remove
the muffler and tailpipe from the
vehicle. cutting the tailpipe may ease
the process of removal.
3
. If your vehicle is equipped with a
catalytic converter, mark a point 4”
from the forward edge of the weld at
the inlet of the catalytic converter on
the downward facing side of the pipe
(see Figure
1 ).
4.
Remove the remaining portion of
the exhaust system from the vehicle.
Retain the T.O.P V-band clamp for
re-use (on Bundles 47582-47587,
use supplied V-band clamp). The
converter must be reinstalled in the
vehicle. Remove the intermediate
pipe from the outlet end of the
converter. At the mark previously
made, cut through the converter pipe
square with the remaining face of the
pipe as shown in Figure
1 .
warnInG: at the outlet of each
exhaust manifold, locate the
short section of tubing that feeds
exhaust up to the turbocharger.
Check these tubes to ensure
that they are not loose, as we
have found several new vehicles
with exhaust leaks in this area.
Correct this condition now or
soon after installation of the
monster exhaust components
to eliminate dangerous exhaust
leaks and poor turbocharger
performance.
ImPorTanT: The catalytic
converter should be inspected.
Diesel catalysts may become
plugged with soot and can cause
a restriction to exhaust flow,
impeding performance. Shine a
powerful flashlight into the inlet
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 gridwork 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 vehicle’s
emissions warranty.
5.
On the passenger side of the
vehicle, temporarily remove the
manifold absolute pressure (MAP)
sensor (Figure
2 ) from its mounting
location by removing the three nuts
from the mounting studs. Save the
nuts for reinstallation later. Set the
MAP sensor out of the way by resting
it in the intake valley of the engine.
6.
Remove both driver- and
passenger-side boost tubes.
7.
Locate the engine lifting hook
at the rear of the engine on the
passenger side, bolted to the cylinder
head. Remove the lifting hook.
This will allow clearance for the
installation of the Power Elbow. It is
not necessary to re-install the hook.
Figure 2
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