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 13)

96328 v.11.0
13
14.
On the passenger side of the
engine compartment, locate the air
conditioning filter/dryer assembly. It will
be necessary to modify the clamping
bracket to allow clearance for the new
tube assembly. Remove the upper filter
dryer bracket by unbolting in three
places. Using a hacksaw or other cutting
tool cut the forward half of the clamp off
in front of the elevated tab across from
the opening of the clamp. Next cut the
remaining tab off of the open side of the
clamp. Reinstall the bracket using a #56
hose clamp provided to secure the filter/
dryer unit to the bracket.
15.
Slide three #52 hose clamps over
the left boost tube. These will be used
later to secure the heatshield in place.
Set both boost tubes into place in the
vehicle. Place two of the 3” silicone
hump hoses onto the intercooler inlet
and outlet, and fasten with the T-bolt
clamps provided. Position two more
clamps on the open ends of the silicone
hoses, and place the intercooler into
the vehicle slipping the boost tubes into
the hoses on the intercooler and the
intercooler into the rubber saddles on
the lower mounting brackets. Do not
tighten these clamps yet.
16.
Place the air conditioning
condenser back into its original position.
Reinstall upper crossbar into truck, using
the original bolts. Reinstall the diagonal
braces to the radiator support and
reattach the power steering cooler to
the right side diagonal.
NOTE: Rotate the upper power steering
fluid tube in the clip to allow the hose
portion to clear the bottom of the right
lower intercooler bracket.
17.
Remove the factory rubber
isolators from the factory intercooler
and install them into the upper brackets
of the Banks intercooler. Install the
original studs through the isolators into
the upper crossbar and tighten them.
Tighten the upper mounting bracket
bolts on the intercooler.
For Late 1999
1 ⁄
2
–2001 models
proceed to Step 23 .
18.
Remove the sensors from the
factory compressor discharge plenum
casting and install them into the Banks
TwinRam intake assembly.
Remove the heating element from the
factory compressor discharge plenum
casting and install it in the Banks Twin
Ram intake assembly.
19.
Slide the two 2” silicone hoses up
the legs of the TwinRam. Slip two #36
hose clamps over each hose and install
the TwinRam to the engine, sliding
the hoses down the legs and onto the
intake stubs, making sure that the
hoses are positioned equally between
the TwinRam legs and the manifold
stubs. Tighten the clamps. Attach the
bracket to the rocker cover using the
8mm x 30mm metric bolts and spacers
provided.
20.
Attach the wastegate control
solenoid to the tab on the TwinRam with
the supplied 1 ⁄
4
-20 x 1 1 ⁄
14
” hex bolt and
washer. Reconnect the wiring harnesses
to the sensors.
21.
Attach the right side boost tube to
the TwinRam using a 3” silicone hump
hose, and two T-bolt clamps.
22.
Place the new O-ring into the
recess in the compressor housing and
attach the compressor discharge elbow
to the compressor housing with the new
v-band clamp provided. A small amount
of bearing grease may be used to hold
the o-ring in position while installing the
elbow. Bolt the compressor discharge
elbow to the TwinRam through the
tab provided for this purpose using
the 5 ⁄
16
” bolt, washers, and nylock nut
provided. Install a 1 ⁄
8
-inch NPT x 1 ⁄
8
-inch
compression fitting (supplied in the
boost gauge kit) in the bung on the
compressor discharge elbow. Sparingly
apply pipe sealant tape or paste on
the male pipe threads, and tighten
the hex on the fitting body (NOT the
compression nut).
23.
Place the O-ring into the recess
in the turbo compressor outlet and
reinstall the factory compressor
discharge plenum casting on the
turbocharger. A small amount of bearing
grease may be used to hold the O-ring
in position while installing the casting.
Slide the hump hoses on the boost
tubes onto the compressor plenum
discharge casting. Reconnect any
wiring or sensor tubes to components
on the compressor discharge casting.
Reconnect boost line to wastegate
actuator.
24.
To reconnect the exhaust
backpressure control valve, hold the
cover on the end of the rod back and
have someone start the engine. When
the rod extends after a few seconds,
push it up onto the valve linkage and
allow the cover to snap back into
position.
25.
Make sure that the ignition is off,
then disconnect all three connectors
from the PCM for easier accessibility to
the wires.
26.
While engine is running, check
for oil leaks around the base of the
turbocharger center section or the
pedestal mount. Repair any leaks before
continuing.
NOTE: The most likely cause of an oil
leak in this installation is a pinched
O-ring at the base of the turbocharger.
For Stinger-Plus installation
proceed to Section 8 .
27.
Reposition the left and right air
deflectors back into their original
positions, and use the pushpins to
attach them to the radiator support.
Reattach the wiring harness removed
from the intercooler mounting studs.
Reinstall the original radiator mount
brackets onto the radiator upper
support. Tighten the bolts. Reattach
the radiator overflow tank to the upper
radiator bracket. Reinstall the jacking
tools to the core support. Reinstall the
grille support to the vehicle using the
original hardware. Reinstall the air
conditioning condenser upper brackets.
Reattach the right and left air deflectors
to the grille support with the original
hardware. Reinstall the hood latch in its
original position.
28.
Reinstall the light bulbs into the
turn signal/marker light combinations,
and reinstall the combinations into
the vehicle. Press them firmly, straight
back into the attaching clips and bolt
them into place. Reinstall the headlight
bulbs into the headlight assemblies.
Be careful not to touch the headlight
bulbs themselves with your fingers, as
oil from your skin can cause damage to
the bulbs. If necessary, clean the bulbs
thoroughly with rubbing alcohol before
reinstalling them.
29.
Turn on the headlights and turn
signals briefly to check for proper
operation.
30.
Reattach the upper radiator air
deflector to the grille support and
upper radiator support with the plastic
pushpins previously removed. Reinstall
the grille by pushing it into the lower
clips. Reinstall the original screws.
31.
Recheck all clamps to ensure that
they are tight before driving the vehicle.
–END, SECTION 7–