Banks Power Dodge Trucks: (Diesel ’98 - 02 5.9L Cummins ISB) PowerPack & Stinger-Plus systems (connects to pump wire) - Manual (Page 12)

TURBOCHARGER INSTALLATION
23.
Note: Some turbos are mounted
with four studs protruding from the
exhaust manifold while others have
two studs in the manifold and two in
the factory turbine housing.
Use the supplied
3 ⁄
8
-24 x 1 3 ⁄
4
” bolts
and crimplock nuts for the upper holes
on the turbine mounting flange.
Install the new turbine inlet gasket
provided and apply a dab of anti-seize
compound to the four turbo mounting
studs. Install the turbocharger on the
exhaust manifold. As the turbocharger
is reinstalled, slip the oil drain tube
into the drain hose. Tighten the
turbocharger mounting nuts to 24 ft-
lbs. Tighten the oil drain hose clamp.
Note: Before slipping any boost tubes
and the corresponding hoses, into
position, ensure that all connection
ends are clean and free of any oil
residue and contaminates. Clean
compressor outlet and all connection
points with a non-oil based solvent
such as Acetone, Mineral Spirits,
Denatured Alcohol or Lacquer Thinner.
Read and follow the manufactures
operation instruction for non-oil based
solvent cleaner.
24.
Align the compressor outlet with
the intercooler hose adapter and
tighten the clamp. Tighten the turbine
housing clamp plate bolts to 100 in-
lbs.
25.
Spin the turbocharger shaft
to make sure it turns freely. If not,
loosen the turbine clamp plate bolts
and check for misalignment between
the turbine housing and turbocharger
center section. Retighten bolts and
check again.
26.
Reconnect and tighten the turbo
oil supply hose.
EXHAUST INSTALLATION
27.
Position the new Banks Monster
T.O.P. turbine outlet pipe onto the
turbine outlet elbow. See Figure 3
on page 6-7. Install the attaching bolts
to hold it in place, but do not tighten
them yet.
28.
Place a 4” muffler clamp onto the
outlet of the turbine outlet pipe, and
then slide the intermediate pipe into
the hanger at the transmission mount,
and onto the turbine outlet pipe. Note:
on extended cab short bed models,
it maybe necessary to shorten the
intermediate pipe. Install the muffler
and tailpipe without clamps and
determine how much to trim based on
the hanger position.
29.
On extended cab/quad-cab long
bed models only, position another
4” clamp onto the outlet end of the
intermediate pipe, and install the
extension pipe onto the intermediate
pipe.
30.
Install the muffler assembly
onto the end of the extension or
intermediate pipe. Temporarily support
the muffler and install the hanger
clamp at the front of the muffler. Snug
the nuts, but do not fully tighten them.
31.
At the rear of the muffler, slip
a 4” clamp over the outlet of the
muffler. Install the tailpipe up over
the axle, and into the muffler outlet.
Place the hanger pins into the rubber
frame mounts behind the axle. Slip
the 5” Monster tailpipe tip on. Keep
the wrapping on until installation is
complete. The tip should be rotated so
the clamp nut is pointing down. Install
the 5” tip so that it hangs past the
end of the tailpipe by 1” for fleet-side
trucks and 2 1 ⁄
2
” for duallies or where
aesthetically pleasing.
32.
Starting from the front of the
vehicle, tighten all exhaust system
attaching bolts and clamps. Make
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96397 v.8.0