Banks Power Ford Trucks: (Diesel ’03 - 07 6.0L Power Stroke) Power Systems- PowerPack & Stinger w EconoMind ('03-07) Compatible w_ Optional PowerPDA - Manual (Page 12)

12
96811 v.10.0
Exhaust System Installation
Use the Bill of Materials chart and
Figure 1a or 1b reference component
nomenclature and location. Use
caution when working in the engine
compartment. Make sure the engine
has been off for several hours and is
cool.
1.
Disconnect the battery ground
cables from each of the batteries.
Secure the cables so that they do
not come in contact with the battery
posts.
2.
Remove the (+) battery cable from
the driver side battery.
3.
Remove the driver side plastic
battery cover. This is accomplished by
depressing a tab at the front and rear
of the cover. Be careful not to damage
the cover, as it will be re-installed.
4.
Remove the driver side battery hold
down clamp (8mm socket).
5.
Remove the driver side battery.
WARNING: When lifting a battery,
excessive pressure on the end
walls could cause acid to spew
through the vent caps, resulting
in personal injury. Lift with a
battery carrier or with hands
on opposite corners. Failure to
follow these instructions may
result in personal injury.
6.
Raise the vehicle and support it
securely with properly weight-rated
safety stands, ramps or a commercial
hoist. Take care to balance the vehicle
to prevent it from slipping or falling.
When using ramps, be sure the wheels
are centered squarely on the topsides.
Place the transmission in park
(automatic) or reverse (manual), set
the parking brake and securely block
the wheels that are on the ground.
CAuTION: DO NOT WORk uNDER
ANy VEHICLE SuPPORTED ONLy
By A JACk. SEVERE INJuRy MAy
RESuLT.
WARNING! The following step
may require the use of a torch
and/ or saw. Proper safety
equipment should be used.
Failure to use proper safety
equipment may result in severe
injury.
7.
From under the vehicle remove
the factory exhaust system from the
catalytic converter back. Starting
at the rear of the vehicle, remove
each component by either cutting
through the pipe near the clamps or
by removing the clamps and heating
the joints with an oxyacetylene torch
to allow crimped pipes to separate.
DO NOT cUT OR DAMAGE cATALYTIc
cONVERTER TUBING DURING THE
REMOVAL PROcESS. To assist in
removal, the T.O.P. should be cut
before the transmission if it is going to
be replaced. Remove the hanger pins
from the rubber hangers with a pry
bar. (Spray lubricant will ease hanger
removal.)
8.
Remove the two (2) nuts attaching
the turbine outlet pipe (T.O.P.) to the
catalytic converter inlet. Loosen and
remove the band clamp that attaches
the rear intermediate pipe to the
catalytic converter outlet. Remove
the catalytic converter assembly
from the vehicle. Remove the v-band-
clamp that attaches the T.O.P. to the
turbocharger and remove the factory
T.O.P. from the vehicle. Retain V-band
clamp for re-assembly.
Note: To assist in T.O.P. removal,
remove the rear engine hoist hook
by removing the two (2) Hex screws
and remove the valve cover heat
shield. The dipstick tube may also be
removed or slightly bent to allow for
T.O.P. removal/installation. Retain all
hardware and parts for reassembly.
9.
For Manual Transmissions
only: The transmission will need
to be lowered to allow for removal
and installation of the T.O.P. Using a
Transmission Jack, support the rear
of the transmission to allow working
room for the T.O.P. and remove the
rear transmission mount and cross
member. Remove the Front drive shaft
support bracket from the cab. Lower
the transmission 4-6” and remove
the factory T.O.P. The transmission
may need to be raised before the
Banks T.O.P. is installed. Install the
Banks T.O.P. Raise the transmission
and reinstall drive shaft bracket,
transmission cross member and rear
transmission mount. Refer to vehicles
owners manual for factory Torque
Specifications.
10.
Loosely place the factory V-band
clamp on the Banks T.O.P. Install the
Banks T.O.P. to the turbine housing.
Loosely snug the V-band clamp
assuring the T.O.P. is aligned properly.
Note: Reinstall the engine hoist
hook and valve cover heat shield if
previously removed.
11.
The catalytic converter inlet will
need to be trimmed to accommodate
the Banks exhaust system. Be careful
not to trim an excessive amount of
tubing. Be sure to wear proper safety
equipment.
IMPORTANT: Diesel catalysts
may become plugged with soot,
which can restrict exhaust flow,
impeding performance. Inspect
the converter by shining a
powerful flashlight into the inlet.
Observe the light through the
other end of the converter. The
full circle of the flashlight should
be visible without any blockage
in the grid work of the catalyst.
If excessive soot is observed,
the catalyst may need to be
cleaned. TAkE PRECAuTIONS to
avoid blowing soot toward the
work area or where it could be
inhaled. ALWAyS use breathing
protection. Also inspect the
catalyst for damage (i.e. chips,
bent corners, etc.) to the grid
work. If your catalytic converter
is damaged, it may be covered
under your vehicle’s emissions
warranty.
12.
With the catalytic converter
removed from the vehicle and the
head pipe removed from the converter,
measure approximately 4” from the
weld and mark the location (this
location should be before any bend,
about 7” rear of the inlet flange). Using
a reciprocating saw or equivalent,
vertically cut and remove 7” from the
converter inlet tubing. Make sure cut is
square (see Figure 2).
13.
Install the supplied Banks front
intermediate pipe onto the previously
installed Banks T.O.P. Loosely install
a supplied 4” exhaust clamp onto the
forward end of the front intermediate
pipe.
14.
Install the supplied 3 1 ⁄ 2 ”
clamp onto the outlet of the front
intermediate pipe. Place the trimmed
catalytic converter onto the previously
installed front intermediate pipe. Be
sure the notch and catalytic converter
pin are properly aligned. Snug the
clamp onto the catalytic converter
inlet, but do not tighten at this time.
15.
Place a supplied 3 1 ⁄ 2 ” clamp
onto the front of the supplied rear
intermediate pipe.
16.
Install the supplied rear
intermediate pipe onto the catalytic
converter outlet. Lightly snug the
3 1 ⁄ 2 ” clamp onto the front of the
intermediate pipe / catalytic converter
outlet.