Banks Power Ford Trucks: (Diesel ’94 - 97 7.3L Power Stroke) Power Systems- PowerPack, Stinger-Plus & Stinger '94-98 3-1_2" Exhaust - Manual (Page 15)

hose connections. There should be a minimum
of 5 ⁄
16
-inch clearance around the connection to
accommodate the thickness of the hose and
clamp. If additional trimming to the sheet-metal
is necessary, remove the intercooler by removing
the upper brackets from the rubber isolator
studs. Remember to have the bumper stud plates
and the transmission-fluid cooler lines in the
proper places when reinstalling the intercooler.
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.
With the intercooler bolted in place, push a
3 x 3-inch silicone hose onto each intercooler
hose connection until the hose bottoms against the
stop on the connection. Slide a pair of #313 T-bolt
clamps onto each hose. Position the clamps so that
they can be tightened from above.
Loosen the clamps and remove the flexible
engine air intake hose from between the
plastic air filter housing duct and the aluminum
elbow. Unbolt and remove the aluminum elbow
and its mounting bracket from the engine.
Push the lower end of the intercooler inlet
tube into the silicone hose on the driver’s
side of the intercooler. The tube will have to
be maneuvered under the A/C hose on air-
conditioned models. Push the inlet tube into
the hose until the tube touches the intercooler
connection, then pull it out approximately 1 ⁄
4
inch.
Install a 3-inch diameter silicone hump
hose and two #313 T-bolt clamps onto the
upper end of the intercooler inlet tube. Insert the
turbocharger compressor outlet elbow into the
hump hose. Place a new compressor outlet O-ring
in the groove on the compressor, then attach the
elbow to the compressor with the original clamp.
Leave the clamp loose enough to rotate the elbow
for adjustment.
Reinstall the aluminum air intake elbow
and flexible air inlet hose onto the engine.
Tighten the clamps on the air inlet and elbow, and
any other clamps loosened or removed from the
elbow.
Adjust the position of the intercooler inlet
tube to provide the maximum clearance to
adjacent parts. Make sure that nothing can chafe or
cut through the hump hose from engine vibration.
Position the hump hose so that it is centered on
the junction of the inlet tube and the compressor
outlet elbow. There should be approximately 1 ⁄
4
-inch
separation between the tube and elbow inside the
hump hose, they should not rub together within
the joint. When all tubes are positioned for best
clearance, tighten the clamps on the hump hose,
the intercooler inlet, and the compressor outlet.
Disconnect the hose between the radiator
and the coolant recovery tank at the
recovery tank end. Insert the lower end of the
intercooler outlet tube into the silicone hose on
the intercooler outlet. The bracket supporting
the battery cable will need to be bent slightly
to provide enough clearance for the tube. Push
the tube all the way in and then pull it out
approximately 1 ⁄
4
-inch. Install a 3-inch diameter
hump hose and two #313 T-bolt clamps onto the
upper end of the intercooler outlet tube.
Remove the two center bolts from the upper
edge of the passenger-side rocker cover.
Install the two hoses removed from the factory
discharge plenum onto Banks TwinRam™ intake
assembly. Push them all the way on until the tube
just begins to come through the hose. Slide two
original clamps onto each hose.
Slide the 3-inch end of the TwinRam into
the hump hose on the intercooler outlet
tube and position the legs of the TwinRam over
the openings on the engine intake manifolds.
Slide the hoses down the legs of the TwinRam
until they are bottomed on the intake manifolds.
Attach the bracket to the rocker cover using the 8
mm x 30 mm metric bolts and spacers provided.
See Figure 13 .
Tighten the lower clamp on each of
the intake manifold hoses. Attach the
tabs on the TwinRam and the compressor
outlet elbow with a 5 ⁄
16
x 1- inch bolt with two
washers and a Nylock nut. Leave this bolt
loose enough for adjustment. Check all bolts,
hoses and wires around the intercooler outlet
tube for clearance. Make any adjustments
necessary, then tighten all clamps and the
5 ⁄
16
-inch nut and bolt.
Mark the plastic grille support as shown in
Figure 14 for cutting. Use a hacksaw to cut
out the areas indicated for intercooler clearance.
Hold the grille support up to the front of the
vehicle and check that the outside corners of
the intercooler end tanks clear the support. Trim
additional material if required to provide 1 ⁄
8
-inch
minimum clearance on each end tank.
Reinstall the grille opening support panel
onto the front of the truck using the original
hardware. Place the turn signal and marker light
bulbs through the proper holes.
Reinstall the valance panel onto the front
of the vehicle with the plastic clips and the
original bolts. CAUTION: When reinstalling the screw
that attaches the bottom of the grille support to the
center of the valance panel, make sure that the end
of the screw does not protrude through the assembly
to the extent that it could come into contact with
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15 P.N. 96322 v.7.0