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 6)

5.
Remove the decorative plastic
cover directly over the engine.
6.
Loosen the clamp holding the
air intake hose at the turbocharger
compressor inlet. Pull the hose free of
the turbo compressor. Disconnect the
boost line attached to the nipple on
the wastegate actuator. Disconnect
wiring and plastic tubing attached to
components on the turbo compressor
discharge plenum casting.
7.
Loosen the four clamps on the
hoses connecting the compressor
discharge plenum casting to the
intake manifolds. Loosen the
clamp attaching the plenum to the
turbocharger compressor outlet and
the intercooler duct. Remove the
compressor discharge plenum from
the engine. Cover the two intake-
manifold hose nipples with clean
rags to prevent foreign objects from
entering the engine.
8.
Disengage the exhaust-
backpressure control actuator rod by
sliding the cover on the end of the
rod back toward the turbocharger
and pulling the rod downward. This
rod is below the turbine housing;
it is not the wastegate actuator
rod that runs across the top of the
turbocharger (see Figure 2).
9.
At the rear of the turbine housing,
loosen and remove the V-band clamp
attaching the turbine housing to the
exhaust inlet casting. Remove the
two bolts attaching the turbocharger
bearing housing to the pedestal base
mounted on the engine. Remove
the turbocharger from the engine by
lifting while lightly tapping the turbine
housing with a hammer.
10.
Remove the two O-rings from
the junction of the turbocharger
bearing housing and pedestal
mount. Place a clean rag over the oil
passages in the pedestal mount and
the exhaust inlet casting to prevent
foreign object entry.
11.
At the back side of the
turbocharger, locate the small e-clip
that retains the actuator rod end on
the wastegate arm. Using a small
screwdriver, carefully pry the clip
off of the wastegate arm and retain
for reuse. CAUTION: This clip is very
small and is easy to lose. It may help to
use a magnet to retain the clip as you
remove it. Loosen the two wastegate
actuator nuts on the turbocharger
compressor housing and remove the
actuator.
12.
Clamp the turbocharger
assembly in a vise. Do not use the
compressor inlet or outlet to clamp
the turbocharger. The compressor
housing is aluminum and could be
damaged. Observe and mark the
relationship of the turbine housing
to the center section of the turbo
assembly.
If a Banks Brake is being installed,
proceed to Step 14.
13.
Remove the exhaust
backpressure control valve from the
factory turbine housing, and install
it onto the new turbine housing with
original hardware. Duplicate the
orientation of the original assembly.
Use anti-seize on the bolts.
14.
Remove the four bolts
securing the turbine housing to the
turbocharger center section. If the
turbocharger is more than a few
months old, it may be necessary
to spray some Liquid Wrench (or
similar rust penetrating lubricant)
into the joint between the turbine
housing and the center section.
Work the housing loose from the
center section by tapping with a
hammer and brass drift or a soft
face hammer. Work from side to
side and use plenty of lubricant until
the housing is loose from the center
section. Pull the housing straight
off of the center section to avoid
damaging the turbine blades.
–END, SECTION 2–
Section 2
TuRBOCHARGER REMOVAL
Figure 2
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