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 7)

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Note: this Manual contains
installation instructions for
Monster exhaust, techni-Cooler,
Quick-turbo and AutoMind
Programmer. Depending on the
system you have purchased, some
of these components may not be
included. Review the entire manual
and select the installation sections
that apply to your product.
For Git-Kit installation, proceed to
Step 2 .
1.
Replace the factory air filter element
with the Banks Ram-Air™ filter.
MoNSTER EXHAuST INSTALLATIoN
2.
Raise the vehicle on a hoist or
safety stands to provide access to the
exhaust system. Loosen the clamp at
the front of the muffler and pry the
muffler and tailpipe hanger pins from
the rubber hangers. Remove the muffler
and tailpipe from the vehicle. Cutting
the tailpipe may ease the process of
removal.
wARNING: At the outlet of each
exhaust manifold, locate the
short section of tubing that feeds
exhaust up to the turbocharger.
Check these tubes to ensure
that they are not loose, as we
have found several vehicles with
problems in this area. Correct
this condition now or soon after
installation of the PowerPack
components to eliminate
dangerous exhaust leaks and poor
turbocharger performance.
For Git-Kit installation, proceed to
Section 6 .
3.
For 1999 vehicles with catalytic
converter: Mark a point 4 inches from
the forward edge of the weld at the
inlet of the catalytic converter on the
downward facing side of the pipe (see
Figure 1A ).
For 1999.5-2003 vehicles without
catalytic converter: Mark a point 15 1 ⁄
2
inches back from the forward side of the
2-bolt flange of the intermediate pipe.
Make the mark on the downward facing
side of the pipe (see Figure 1B ).
4.
Loosen the two bolts at the front of
the catalytic converter or intermediate
pipe and pry the hanger pin on the pipe
inlet from the rubber hanger. Remove
the pipe assembly from the vehicle.
Disconnecting the extension pipe from
the outlet of the converter may ease the
process of removal.
IMPoRTANT: If the vehicle is equipped
with a catalytic converter, it should be
inspected. Diesel catalysts may become
plugged with soot and can cause a
restriction to exhaust flow, impeding
performance. Shine a powerful flashlight
into the inlet end of the converter.
Observe the light through the other
end of the converter. The full circle of
the flashlight should be visible without
any blockage in the gridwork of the
catalyst. If excessive soot is observed,
the catalyst may need to be cleaned.
TAKE PRECAUTIONS to avoid blowing
soot toward the work area or where
it could be inhaled. ALWAYS use
breathing protection. Also inspect
the catalyst for damage (i.e. chips,
bent corners, etc.) to the gridwork. If
your catalytic converter is damaged, it
may be covered under your vehicle’s
emissions warranty.
5.
Using a reciprocating saw, make a
cut in the turbine outlet pipe about an
inch downstream of the factory heat
shield being careful not to damage the
heat shield, as it will be reused. Remove
the V-clamp that secures the factory
turbine outlet pipe to the turbocharger
outlet. Remove both portions of the pipe
from under the vehicle.
6.
At the mark previously made, cut
through the pipe square with the
remaining face of the pipe.
7.
Cut through the metal straps that
hold the heat shield onto the factory
turbine outlet pipe. Secure the heat
shield to the Banks Monster ® T.O.P.
turbine outlet pipe using the clamps
provided (see Figure 2 ).
–END, SECTION 3–
Section 3
MoNSTER ® EXHAuST INSTALLATIoN (PART 1 oF 2)
Figure 1A- 1999 with Catalytic Converter
Figure 1B- 1999.5-2003 without Catalytic Converter
Figure 2- Securing Heat
Shield