Banks Power Dodge Trucks: (Diesel ’03 - 07 5.9L Cummins) Power Pack & Stinger System & EconoMind, '06-07 Compatible with Banks iQ - Manual (Page 10)

10
96822 v.4.0
1.
Disconnect the battery ground
cables from each of the batteries.
Secure the cables so that they do
not come in contact with the battery
posts during the installation.
2.
Raise the vehicle and support it
with properly weight rated safety
stands, ramps or a commercial hoist.
Follow the manufacturer’s safety
precautions. Take care to balance the
vehicle to prevent it from slipping or
falling. When using ramps, be sure the
front wheels are centered squarely on
the topsides; place the transmission in
park; set the parking brake and place
blocks behind the rear wheels.
CAuTIoN: Do NoT WoRK uNDER
ANy VEHICLE SuPPoRTED oNLy
By A JACK. SEVERE INJuRy MAy
RESuLT.
WARNING! The following step
requires the use of a torch and/or
saw. Proper safety equipment
should be used. Failure to use
proper safety equipment may
result in severe injury.
3.
Starting at the rear of the
vehicle, remove the tailpipe near the
muffler clamps by cutting through
the connection or by removing the
clamps and heating the joints with an
oxyacetylene torch to allow crimped
pipes to separate. Remove the tailpipe
from the vehicle.
4.
Remove the clamps on the
catalytic converter to front muffler
or if applicable, the intermediate
pipe connection. TAKE CAuTIoN To
NoT CuT oR DAMAGE CATALyTIC
CoNVERTER TuBING. Separate the
muffler intermediate pipe to catalytic
converter connection.
Note, the use of an oxy-acetylene
torch may be necessary. Remove
the muffler hanger pins from the
rubber hangers with a pry bar (Spray
lubricant will ease hanger removal)
and remove the muffler/intermediate
pipe or muffler assembly from the
vehicle.
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 grid
work 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 grid work. If your
catalytic converter is damaged,
it may be covered under your
vehicle’s emissions warranty.
5.
For Crew Cab Long Bed & Mega
Cab models (160.5” wheelbase)
ONLY, install a 4” exhaust clamp onto
the front of the Banks intermediate
pipe. Install the intermediate pipe
onto the catalytic converter outlet.
Install the intermediate pipe hanger
onto the corresponding rubber
hanger. Loosely snug the 4” clamp.
6.
For all models, install the Banks
front muffler hanger clamp (single
pin) onto the Monster muffler inlet.
Also install a 4” exhaust clamp onto
the muffler inlet. Install the muffler
inlet (see markings on muffler body)
onto the Banks intermediate pipe /
catalytic converter. Orient the muffler
such that the “Banks Monster” logo is
facing towards the frame and is level
with the ground. Install the hanger
clamp pin into the corresponding
rubber hanger with the hanger pins
facing forward (see Figure 2). With
the muffler inlet fully inserted, loosely
tighten the 4” exhaust clamp on the
muffler inlet swedge.
NOTE: Once the pipe has been
completely engaged in the slip
joint, it should be marked with a
marker, scribe or tape for reference
when tightening clamps later in the
installation. Each slip joint in the
system should be marked in this
fashion. When the exhaust system is
being adjusted to align the hangers,
the slip joints can be adjusted so that
the reference mark is no more than
1 ⁄ 4 ” away from its original position.
Step 7 thru 11 for single exhaust
Step 12 thru 23 for split dual
Single exhaust
7.
Install a 4” exhaust clamp on the
muffler outlet. Adjust the hanger
clamp to a position that best supports
the muffler.
8.
Route the tailpipe over the rear
axle housing and into the muffler
outlet. Install the tailpipe hanger pin
into the corresponding rubber hanger.
Loosely snug the 4” clamp on the
muffler outlet.
9.
Install the 5” Monster tailpipe tip
on the exhaust. Keep the wrapping
on until installation is complete. The
tip should be rotated so the drain
hole is facing down. Adjust the tip
past the edge of the body or where
aesthetically pleasing.
10.
With everything positioned
properly, begin to tighten the clamps
starting with the ones closest to the
turbo and working your way back.
Evenly torque the exhaust clamps to
35 ft-lbs. Make sure that each slip is
fully inserted (+/- 1 ⁄ 4 inch).
Note: Whenever possible, tack
weld slip connections to prevent
disengagement is recommended.
11.
Remove the protective covering
from the tailpipe tip. caution: The
protective covering may ignite and
burn if not removed prior to running
the engine.
Proceed to Section 2.
Figure 2