Banks Power Ford Trucks: (Diesel ’99 - 03 7.3L Power Stroke) Power Systems- Git-Kit, Stinger, Stinger-Plus & PowerPack '99-03 F-450 & F-550 pickup (For 3-1_2" exhaust only) - Manual (Page 12)

12
96328 v.11.0
For Git-Kit Installation, proceed to
Section 9 .
For Stinger Installation, proceed to
Section 8 .
For Stinger-Plus Installation,
proceed to Step 23 .
For PowerPack Installation,
continue with Step 1 .
TECHNI-CooLER INSTALLATIoN
1.
Remove the factory intercooler
plumbing from the vehicle. Loosen the
clamps on the boost tubes and remove
the boost tubes. (It is assumed that the
compressor discharge plenum casting
has been removed from the vehicle at
this point.)
2.
To remove the factory intercooler,
it will be necessary to remove the grille
assembly. At the front of the vehicle,
remove the pushpins holding the rubber
air deflector to the grille support and
remove the air deflector. Remove the
screws at the top of the grille, dis-
connect the lower clips with a small
screwdriver, and remove the grille.
3.
On each side, remove the bulb from
the headlight assembly. Remove the two
bolts below the turn signal/marker light
combination and remove the assembly
by pulling it directly forward. Remove
the bulbs from the turn signal/marker
lights or disconnect the connectors to
separate it from the vehicle.
4.
Remove the pushpin and the hood
cable clip to disconnect the left air
deflector from the radiator core support.
Separate the left air deflector from the
grille support by removing the pushpins
from the bracket on the grille support.
Repeat this process for the right side air-
deflector, removing the pushpins from
the core support and grille support.
5.
Remove the upper a/c condenser
brackets. Remove the grille support
bracket attaching bolts and remove
the grille support from the vehicle. The
a/c condenser needs to be lifted at
the same time as the grille support is
pulled away from the vehicle. Pull from
the bottom at first to pivot the support
upwards as you pull forward. The a/c
condenser will fit between the air
deflector brackets as the support moves
forward. Be cautious of the corners of
the front fenders as the condenser is
lifted up. It may be beneficial to cover
the fender corners with masking tape or
some other form of protection.
6.
Scribe a line around the hood latch
with a sharp instrument to mark the
location of the latch, then remove the
latch from the upper radiator support.
Do not remove the cable from the latch.
Move the latch out of the way.
7.
Remove the jacking tools from the
core support and remove the coolant
reservoir bolt from the jacking tool
mount bracket. Remove the upper
radiator brackets. Remove the upper
diagonal brace bolts from the upper
radiator core support. Remove the
wiring harness from the intercooler
mounting studs and remove the studs
from the upper radiator support.
Remove the six bolts on each end of
the upper radiator core support cross
bar and remove the upper core support
cross bar from the vehicle. It may be
necessary to pry the cross bar up out of
the slot in the core support.
8.
Pull the air conditioning condenser
up out of the lower brackets and swing
it up over the engine and out of the
way. Be careful of the tubes that carry
pressurized refrigerant. Do not bend the
tubes as they are aluminum, and can be
easily damaged. Using a bungee cord or
similar equipment, temporarily suspend
the condenser from the hood of the
vehicle, out of the way.
9.
Remove the bolt attaching the power
steering cooler to the diagonal brace.
Remove the diagonal braces from the
lower radiator core support. Tilt the
intercooler forward and remove it up
and out of the vehicle.
NOTE: Later models do not have
diagonal braces, unbolt power steering
cooler from brackets as required.
10.
Using the four 1 ⁄
4
”-28 x 2” bolts,
washers and nylock nuts, loosely bolt
the new lower intercooler mounting
brackets to the lower mounting
crossbar. Position this mounting
assembly into the vehicle as shown
in Figure 4 . Using the lower diagonal
brace mounting holes as locations,
position the crossbar assembly level
in the vehicle and temporarily bolt the
brackets to the core support using
the lower diagonal brace bolts. Using
the brackets as a template, mark the
four holes necessary to complete
the attaching of the lower mounting
brackets, and drill four 1 ⁄
8
” holes in those
positions. Attach the lower mounting
brackets to these holes in the core
support with the four #10 sheet metal
screws provided. Now remove the two
factory diagonal brace bolts.
NOTE: On later model vehicles without
diagonal braces and associated bolt
holes, slide the lower intercooler
mounting crossbar, with brackets
loosely attached, up the sides of the
core support opening until the brackets
come against the bottom edges for the
“ears” that overlap the inside edge of
the core support opening. If the lower
intercooler mounting brackets cannot
be slid out far enough on the crossbar
to contact the sides of the core support
opening at this elevation, slide each
bracket outward on the crossbar as far
as it will go, then tighten the 1 ⁄
4
” thru-
bolts, set the crossbar assembly in the
core support opening, and level it to the
vehicle.
With the crossbar assembly positioned
in the core support opening as
indicated, scribe the core support
through the four holes on the inside
edges of the brackets, being certain that
the front flanges of the brackets (with
the single unused bolt hole) are against
the face of the core support. Drill four
1 ⁄
8
” holes at the scribed locations, then
attach the brackets to the core support
with four #10 sheet metal screws
provided.
11.
Remove the rubber air deflector
strips from the ends of the factory
intercooler by snipping the plastic ties
that run through the intercooler fins.
Attach the deflectors to the inboard
side of the 3-hole tabs on the Banks
intercooler by installing one 1 ⁄
4
-28 x
1” hex bolt, washer, and nylock nut
assembly through the bottom hole
on the lower tab on each end of the
intercooler and the existing bottom hole
on each deflector strip. The remaining
three holes on the deflector strips
will not line up with the holes in the
intercooler. Drill or punch a new set of
holes in the deflector strips to line up
with the upper holes in the lower tabs
on the intercooler, then install a 1 ⁄
4
-28
x 1” hex bolt, washer, and nylock nut
assembly in each of these locations.
(See Figure 4 ) Drill or punch a third set
of holes through each deflector strip to
line up with the middle hole in the upper
tabs on the intercooler.
12.
Loosely bolt the upper brackets to
the Banks Techni-Cooler as shown in
Figure 4 using four 1 ⁄
4
-28 x 1” hex bolts,
1 ⁄
4
” washers and nylock nuts through the
outboard holes in the two upper tabs on
the intercooler.
13.
Trim the rubber air deflector to
clear the upper bracket attaching nuts
so the deflector will sit flat against
the tab on the intercooler. Attach the
deflectors to the intercooler at the
middle hole in each upper tab using
another pair of 1 ⁄
4
”-28 bolt assemblies.
Do not tighten these bolts yet.
Section 7
BANKS TECHNI-CooLER ® INSTALLATIoN