Banks Power Ford Trucks: (Diesel ’99 - 03 7.3L Power Stroke) Power Systems- Stinger, Stinger-Plus & PowerPack systems '19991_2-2003 F250_F350 Trucks & Excursion (non-cat) - Manual (Page 13)

45.
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.
46.
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.
47.
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 19991⁄2–2003 models,
proceed to Step 53.
48.
Remove the sensors from the
factory compressor discharge plenum
casting and install them into the
Banks TwinRam intake assembly.
Remove the heating element from
the factory compressor discharge
plenum casting and install it in the
Banks TwinRam intake assembly.
49.
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.
50.
Attach the wastegate control
solenoid to the tab on the TwinRam
with the supplied 1 ⁄ 4 -20 x 11 ⁄ 14 ” hex
bolt and washer. Reconnect the
wiring harnesses to the sensors.
51.
Attach the right side boost tube
to the TwinRam using a 3” silicone
hump hose, and two T-bolt clamps.
52.
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 54.
53.
(All models for Stinger-Plus
installation): 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.
If a Banks Brake is being installed,
proceed to Step 55.
54.
To reconnect the exhaust
backpressure control valve, hold the
cover on the end of the rod back
and have someone start the engine.
When the rod extends after a few
seconds, push it up onto the valve
linkage and allow the cover to snap
back into position. WARNING! Stay
clear of moving parts such as engine
cooling fan and belts. Do not drive
the vehicle until the remainder of the
installation is complete.
55.
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.
For Stinger-Plus installation
proceed to Step 62.
56.
Make sure that the boost tubes
clear all moving parts, and that the
hoses do not chafe on any sharp
edges. Tighten all of the boost tube
clamps.
57.
Reposition the left and right air
deflectors back into their original
positions, and use the pushpins to
attach them to the radiator support.
Reattach the wiring harness removed
from the intercooler mounting studs.
Reinstall the original radiator mount
brackets onto the radiator upper
support. Tighten the bolts. Reattach
the radiator overflow tank to the
upper radiator bracket. Reinstall the
jacking tools to the core support.
Reinstall the grille support to the
vehicle using the original hardware.
Reinstall the air conditioning
condenser upper brackets. Reattach
the right and left air deflectors to
the grille support with the original
hardware. Reinstall the hood latch in
its original position.
58.
Reinstall the light bulbs
into the turn signal/marker light
combinations, and reinstall the
combinations into the vehicle. Press
them firmly, straight back into the
attaching clips and bolt them into
place. Reinstall the headlight bulbs
into the headlight assemblies. Be
careful not to touch the headlight
bulbs themselves with your fingers,
as oil from your skin can cause
damage to the bulbs. If necessary,
clean the bulbs thoroughly with
rubbing alcohol before reinstalling
them.
59.
Turn on the headlights and turn
signals briefly to check for proper
operation.
60.
Reattach the upper radiator
air deflector to the grille support
and upper radiator support with the
plastic pushpins previously removed.
Reinstall the grille by pushing it into
the lower clips. Reinstall the original
screws.
61.
Recheck all clamps to ensure
that they are tight before driving the
vehicle.
–END, SECTION 5–
96334 v.5.0
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