Banks Power Dodge Trucks: (Diesel ’03 - 07 5.9L Cummins) Intake- Big Hoss Intake Manifold System '03-07 235, 250, 305 and 325 HP, Dodge Cummins 5.9L (24-valve) Trucks - Manual (Page 11)

96774 v.5.0
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plastic fastener where the clip
nut was installed.
15.
Bend dipstick tube as
required allowing dipstick tube
bracket to be fastened to the
clip nut on the throttle controller
with an M6 x 50mm hex bolt and
1-inch long spacer. Install bolt
with M6 split lock washer and
1 ⁄
4
SAE washer thru spacer into
clip nut on controller and tighten.
(See Figure 6)
16.
If the Big Hoss intake
manifold is being installed along
with a Banks Techni-cooler
charge air-cooler in a Dodge pick-
up, install the Techni-cooler kit
at this time, then continue with
these instructions at the point
where the boost tube is to be
installed in the Techni-cooler kit.
Once the boost tube and related
hardware is installed, complete
any remaining steps in the
Techni-cooler kit.
17.
Thread a 1 ⁄
4
-28 hex jam nut
onto each of the four 1 ⁄
4
-inch
rod-end bearing. Thread a 1 ⁄
4
-inch
rod-end bearing into each end of
the two 3 ⁄
8
x 5-inch long hex links.
These links will span each side
of the 4-inch dia. inlet hose joint
on the intake manifold to prevent
the boost tube from blowing out
under high boost conditions.
18.
The links and bearing should
be adjusted to approximately a 6
3 ⁄
4
-inch center-to-center distance.
This will provide an average of 1 ⁄
8
to 1 ⁄
4
-inch gap at the hose joint
between the manifold and the
boost tube. If you are fabricating
a boost tube for a custom
installation, locate bolt tabs on
the boost tube to provide the 1 ⁄
8
to 1 ⁄
4
-inch gap at the hose joint.
once adjusted, tighten the jam
nuts against the links.
19.
install the 4-inch dia. x 3 1 ⁄
2
-
inch long silicone hose onto the
inlet hose nipple on the intake
manifold. Push the hose on the
nipple until it comes against the
stop bead on the manifold. Slide
two 4.25-inch hose clamps over
the hose, but do not tighten.
Push the boost tube into the hose
until It contacts the manifold
nipple, then pull it out 1 ⁄
8
to 1 ⁄
4
inch to provide the recommended
gap.
20.
Tighten the hose clamps,
make sure the clamps are
positioned behind, not over, the
hose bead part of the manifold
and boost tube hose nipples.
21.
Insert a 1 ⁄
4
-20 x 12 pt. bolt
thru a rod-end bearing in one of
the link assemblies and thread it
into the rear “ear” on the 4-inch
inlet hose joint on the Big Hoss
manifold and tighten.
22. Install the remaining link
assembly on the front “ear” on
the Big Hoss manifold using
either a 1 ⁄
4
-20 x 3 ⁄
4
12pt. bolt, or,
if a stud was installed in step 12,
by passing the rod-end over the
1 ⁄
4
X 1 1 ⁄
4
- inch stud and using
the third 3 ⁄
8
x 5-inch hex link as a
nut on the stud and tighten. See
Figure 7 and 8.
23.
Bolt the free end of each link
assembly to the upper side of
the two tabs on the boost tube
using a pair of 1 ⁄
4
-28 x 1 hex bolts,
1 ⁄
4
-inch An washers, and 1 ⁄
4
-28
Nylock nuts.
24.
If the dipstick was mounted
to the top of the throttle
controller in steps 15, the
installation of the Big Hoss
manifold is complete. otherwise,
bend the dipstick tube as
required to allow the dipstick
tube bracket to be bolted to the
top of the vertical hex link. install
a 1 ⁄
4
-28 x 1” hex bolt, a 1 ⁄
4
- inch
split lock washer, and two 1
⁄4
-inch
SAE washers thru the dipstick
tube bracket and into the hex
link, then tighten the bolt. This
completes the installation of the
Big Hoss intake manifold.
-EnD, SEcTion 7-
Figure 6