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 5)

96774 v.5.0
5
All position references for
bandsawing and machining are
measured from the front cylinder
headbolt dowel hole (right front
hole) next to the thermostat
pocket. Viewing the head from
above, locate this hole and the
row of head bolts down the right
side of the head. (7 total) From
the centerline of this row of head
bolt holes, measure 6 1 ⁄
4
inches
toward the intake side and scribe
a line the length of the head. (See
Figure 1) This should place the
line about 1 ⁄
4
inch away from the
outer edge of the rocker cover
rail flange on the intake gasket
surface. This will be the bandsaw
cut line to remove the bulk of the
cast-on intake manifold trough.
Tape a piece of heavy cardboard
to the head gasket surface of
the cylinder head to protect it
from scratches caused by the
saw table. A guide bar may be
clamped to the saw table to align
with exhaust port gasket face as
the head is moved forward. cut
the intake trough from the head
just outside the scribe line. This
cut will leave approximately .220
inch of material on the intake
face of the head for machining.
-EnD, SEcTion 3-
Section 3
BANDSAw rouGH CuT
FRONT HEADBOLT
DOWEL HOLE
6
1 ”
4
BANDSAW
CUT LINE
Figure 1