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 4)

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Table of Contents
Section 1 . . . . . . . . . . . . . . . . 4
System Description
Section 2 . . . . . . . . . . . . . . . . 4
cylinder Head Preparation
Section 3 . . . . . . . . . . . . . . . . 5
Bandsaw Rough cut
Section 4 . . . . . . . . . . . . . . . . 6
Machining Manifold Face
Section 5 . . . . . . . . . . . . . . . . 8
Drilling and Tapping
Section 6 . . . . . . . . . . . . . . . . 8
Port Matching
Section 7 . . . . . . . . . . . . . . . 10
Intake Manifold to cylinder Head
Assembly
Bill of Materials. . . . . . . . . . 13
The Banks Big Hoss Intake
Manifold and Techni-cooler
system is intended for the
driver who wants engine
performance levels well above
and beyond those which can
be achieved by only bolt-on
external components. The system
dramatically increases airflow
and air density by removing
intake restrictions while reducing
charge-air temperature. This
provides increased performance
with a given boost or even
greater performance at elevated
boost levels. The intake manifold
portion of the system may
be purchased separately for
customers who already have the
Banks Techni-cooler installed
in their vehicle. The Big Hoss
manifold is ideal for custom
and competition installations
where extensive cylinder head
and injection modifications are
planned.
Installation of the Banks Big Hoss
intake manifold dramatically
reduces intake air restrictions
through the removal of the
internal intake manifold portion
of the cylinder head and the
elimination of the separate
elbow casting. Furthermore, the
removal of the cast-on intake
manifold allows the engine
assembler access to the intake
ports for the optional porting and
blending of the intake runners.
Important
Installing the Banks Big Hoss
manifold requires removing the
cylinder head, disassembly and
removal of all injection and valve
train components, sawing off
the intake portion of the cylinder
head, and re-machining the head
to accept the manifold. Persons
performing this work should be
familiar with engine disassembly
and assembly procedures, and
should have a shop manual for
the engine and vehicle to be
modified. Access to a machine
shop with an industrial band
saw and vertical milling machine
is required. A block and head
surfacer may be used for the
flange finishing operations.
A machining drawing for the
milling and tapping operations is
provided for your machinist.
-EnD, SEcTion 1-
The cylinder head must be
removed from the engine
and completely stripped of all
valve train and fuel injection
components. Remove the intake
inlet elbow and manifold cover
plate from the intake side of
the head. The head should be
thoroughly cleaned and inspected
for any defects or damage
(cracks, leaks, or porosity) that
would make it unsuitable for
high performance use. See shop
manual for disassembly and
inspection procedures, repair or
replace the head as is necessary.
-EnD, SEcTion 2-
Section 2
CyLINDer HeAD PrePArATIoN
Section 1
SySTeM DeSCrIPTIoN