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 4)

Dear Customer,
If you have any questions
concerning the installation of
your Banks Power System,
please call our Technical Service
Hotline at (888) 839-2700
between 7:00 am and 5:00 pm
(PT). If you have any questions
relating to shipping or billing,
please contact our Customer
Service Department at
(888) 839-5600.
Thank you.
1.
For ease of installation of your
Banks system, familiarize yourself
with the procedure by reading the
entire manual before starting work.
2.
The exploded view (pages 10-11)
provides only general guidance. Refer
to each step and section diagram in
this manual for proper instruction.
3.
Throughout this manual, the
left side of the vehicle refers to the
driver’s side, and the right side to the
passenger’s side.
4.
Disconnect the ground cable from
the battery (or batteries, if there are
two) before beginning work.
5.
Route and tie wires and hoses a
minimum of 6” away from exhaust
heat, moving parts and sharp
edges. Clearance of 8” or more is
recommended where possible.
6.
When raising the vehicle, support
it on properly weight-rated safety
stands, ramps or a commercial hoist.
Follow the manufacturer’s safety
precautions. Take care to balance
the vehicle to prevent it from slipping
or falling. When using ramps, be
sure the front wheels are centered
squarely on the topsides; put the
transmission in park; set the hand
brake; and place blocks behind the
rear wheels.
Caution! Do not use floor jacks to
support the vehicle while working
under it. Do not raise the vehicle
onto concrete blocks, masonry
or any other item not intended
specifically for this use.
7.
During installation, keep the work
area clean. Do not allow anything
to be dropped into intake, exhaust,
or lubrication system components
while performing the installation, as
foreign objects will cause immediate
turbocharger and/or engine damage
upon start-up.
Tools Required:
•
1 ⁄ 2 ” and 3 ⁄ 8 ” drive ratchets with
inch and metric sockets and 1 ⁄ 2 ” and
3 ⁄ 8 ” drive extension
• Inch and metric combination or
open-end wrenches
• Standard screwdriver
• Clean shop towels or rags
• Pry-bar
• Reciprocating saw
Highly recommended tools and
supplies:
• Inch-pound and foot-pound torque
wrenches
• Penetrating oil or light lubricant
spray
General Installation Proctices
Table of Contents
General Installation Practices ........... 4
Recommended practices, tools, and
supplies for installation
Section 1 ............................................. 5
Exhaust Installation (Part 1 of 2)
Section 2 ............................................. 6
Turbocharger Removal
Section 3 ............................................. 7
Turbine Housing and Compressor
Wheel Installation
Section 4 ............................................. 8
Exhaust Installation (part 2 of 2)
Section 5 ........................................... 12
Banks Techni-Cooler ® Installation
Section 6 ........................................... 15
Dynafact ® Instrumentation Installation
Section 7 ........................................... 18
Banks Ottomind ® Installation
Section 8 ........................................... 21
Checking Engine Performance
Section 9 ........................................... 22
Service Tips
List of Components .......................... 24
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