Banks Power Ford Trucks: (Diesel ’03 - 07 6.0L Power Stroke) Intake- Techni-Cooler Intercooler Assembly F250-F350-F450F550 Trucks & Excursions - Manual (Page 13)

55.
For 2003 to 2004 vehicles,
install the factory replacement intake
manifold gasket in the groove on
the intake manifold. For 2005-07
vehicles, install the factory
replacement intake manifold gasket
on the High Ram.
56.
Slide the High-Ram over the
installed studs.
57.
Place the thread sealing washers
on the two driver side studs. Use a
twisting motion to thread the sealing
washers over the threaded portion of
the studs to avoid tearing the seals.
Install standard flat washers on the
passenger side studs and on top of
the thread sealing washers, as shown
in Figure 14.
58.
Secure the High Ram with (4x)
1 ⁄ 4 ”-20 Nylon locking nuts. Torque to
9 ft-lbs.
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.
59.
Install the driver and passenger
side boost tubes and connection
hoses as shown in Figure 12.
The connection hoses should be
slid firmly against the hose stops
provided on the cAc and High
Ram. Allow a minimum 1 ⁄ 8 ” air gap
between CAC, High Ram and boost
tubes.
Note: The a/c line on the passenger
side may need to be bent to provide
clearance for the boost tube. On
2003 to 2004 vehicles: The brake
line on the driver side may need to
be slightly bent to provide additional
clearance for the boost tube. On
2005-07 vehicles: One of the power
steering fluid lines may need to be
bent to provide clearance for the
driver side boost tube.
60.
The hose clamps on the High
Ram must be positioned as shown in
Figure 15 to avoid contact with the
hood.
62.
Tighten the hose clamps to 75
inch-lbs (not ft-lbs!).
63.
Re-install the plastic driver side
battery box. Torque the attachment
bolts to 12 ft-lbs. On 2005-07
4-wheel drive vehicles only: Reinstall
the electronic module mounting
bracket that was removed with the
plastic battery tray.
64.
Re-install the driver’s side
battery, battery hold down clamp,
and plastic battery cover. Torque the
hold down clamp retaining bolt to 89
in-lbs (not ft-lbs!).
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.
65.
For 2005-07 4-wheel drive
equipped vehicles only: Re-install the
electronic module near the driver
side battery. The module is shown in
Figure 5.
66.
Re-install the air filter assembly
box and air box front cover.
67.
Re-install the driver and
passenger (+) and (-) battery cables.
-END, SECTION 5-
Figure 15
96780 v.9.0
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