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 9)

96328 v.11.0
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1.
For 1999.5-2003 model year:
Remove the five bolts around the
outside of the compressor cover and
carefully remove the cover by pulling it
straight off the turbocharger assembly,
avoiding contact with the compressor
wheel. Use caution to avoid damaging
the sealing o-ring around the outside
diameter of the compressor back plate.
2.
Secure the turbine wheel in a vise by
clamping the hub of the turbine wheel.
Remove the compressor wheel using a
5 ⁄
8
” socket. Install the new compressor
wheel provided in the kit. Slide the
wheel onto the shaft and lightly turn
the wheel to engage the threads. If
the wheel does not easily engage the
threads, back the wheel off and try
again. It may be helpful to listen for
a small click while rotating the wheel
counterclockwise, and then rotate the
wheel clockwise again. Once the wheel
has engaged the threads properly,
spin it on by hand until snug. Using a
torque wrench, tighten the assembly
to 100 in/lbs. Reinstall the compressor
cover, making sure that the o-ring is
properly seated against the backplate
of the turbo. Reinstall the five bolts and
tighten.
3.
Place Banks Quick-Turbo ® turbine
housing onto the center section, again
paying careful attention to the turbine
blades. Apply some anti-seize to the
four bolts and reinstall them. Check the
orientation of the assembly, then tighten
the bolts.
4.
Install the Banks Big Head actuator
onto the turbocharger. Tighten the lock
nuts on the mounting studs and adjust
the rod end until the hole aligns with
the wastegate arm pin. Turn the rod
end link clockwise an additional six full
turns, such that it will add preload to
the wastegate. Apply a regulated supply
of air pressure to the nipple on the
actuator until the rod extends enough to
slip over the wastegate arm pin. Install
the e-clip onto the wastegate arm pin to
retain the actuator rod. Tighten the jam
nut down on the end link.
For Stinger installation proceed to
Section 6 .
5.
Reinstall the turbocharger onto
the pedestal assembly on the engine.
Make sure the sealing area on the
pedestal assembly and the bottom of
the turbocharger are clean, and the
new O-rings provided are in place, then
bolt the turbocharger to the pedestal.
Reinstall the V-band clamp attaching
the turbine housing to the exhaust inlet
casting.
6.
Reinstall the air inlet hose to the
turbocharger compressor air inlet.
–END, SECTION 5–
Section 5
QuICK-TuRBo ® AND CoMPRESSoR wHEEL INSTALLATIoN
1.
Loosely clamp the upper portion of
the turbine outlet pipe to the exhaust
backpressure control valve on the
turbocharger. Slide two 3 1 ⁄
2
-inch exhaust
clamps over the lower portion of the
turbine outlet pipe and install the pipe,
aligning the hanger pin in the rubber
hanger. Reinstall the catalytic converter
or intermediate pipe by slipping the inlet
into the lower portion of the turbine
outlet pipe (see Figure 4 ).
NOTE: On some Powerstrokes a ground
strap is bolted on back of the cylinder
head. This bolt may interfere with the
Banks turbine outlet pipe. If so, remove
the bolt and relocate it in the cylinder
head.
2.
Slide a 3 1 ⁄
2
-inch exhaust clamp over
the inlet of the muffler. Reinstall the
extension pipe, if removed, and install
the Banks Dynaflow ® muffler onto the
end of the intermediate pipe, aligning
the slot with the raised tab. Insert the
hanger pins into the rubber hangers at
the front and back of the muffler.
3.
Slide a 3 1 ⁄
2
-inch exhaust clamp over
the outlet of the muffler. Install the
Banks Monster ® tailpipe over the rear
axle and into the outlet of the Banks
Dynaflow muffler. Insert the hanger pin
into the rear rubber hanger.
4.
Position all the exhaust components
such that all the hanger pins are parallel
with the ground and all exhaust tubing
is located properly. Lightly tighten the
clamps to maintain position. The tailpipe
tip should be positioned 2 to 2 1 ⁄
2
inch
below the bottom edge of the fender.
All hangers should be level and hanging
slightly forward (see Figure 5 ).
5.
With everything positioned properly,
begin tightening all exhaust clamps,
beginning with the V-band clamp at the
turbine discharge, and working down
stream.
–END, SECTION 6–
Figure 5- Hanger Positioning
Section 6
MoNSTER ® EXHAuST INSTALLATIoN (PART 2 oF 2)