Banks Power Ford Motorhomes: (Gas ’93 - 98 7.5L Class-A) PowerPack System (Class-A, Ford chassis, w_ cat.) For Use w_ 460 EFI Engine - Manual (Page 4)

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facTory exhausT manifold bolT removal
because of a condition inherent in the factory
design, the exhaust manifolds may crack the
manifold-to-head bolts as manifolds undergo
changes in length from expansion and contraction.
in some cases, these forces may also crack the
exhaust bolt bosses on the cylinder head. cracked
bolts will not show any external damage, but bolt
heads may break off upon removal.
we recommend that you do the following to
minimize the possibility of broken manifod bolts.
apply a penetrating oil (such as liquid
Wrench) to the area where each exhaust
manifold bolt enters the cyliner head.
if some bolts turn more easily than others,
remove these bolts first. this may reduce
stress on the tighter bolts.
the use of an impact wrench is
recommended, when available. the
hammering action of the impact tool helps loosen
the bolts better than the steady pull of a wrench
handle.
if a manifold bolt does break off, it may be
removed by one of the followingmethods.
if there is enough thread remaining on the
broken bolt to install two nuts, it may be
possible to jam the nuts together to turn the bolt.
tighten the nuts against each other, then turn the
bolt by turning the inner nut countercockwise.
if there is some thread protruding from the
head, but not enough to install double nuts,
it may be possible to grip the bolt with a tool such
as a vise-gri pliers.
if the bolt has broken off near or below the
flange surface of the head, it may be drilled
and removed with a screw extractor, such as an
easy-out. make sure you drill the pilot hole in the
center of the broken bolt with the proper size drill
for the extractor used. if the hole is not on center,
it may cause the extractor to bite into the threads
in the head, preventing the extractor from turning.
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installation instructions
1.
remove the “dog house” cover from the engine
for access.
2.
if a heavy duty hoist is available, raise the vehicle
and remove the front wheels for easier access. if
the rear wheels remain on the ground, block the rear
wheels.
disconnect all cables from the battery(s).
4.
starting from the rear of the vehicle and working
forward, remove the exhaust system from the
vehicle. leave exhaust pipe hangers in place on the
chassis.
NOTE: Some joints may require the heat from a torch
to loosen them for disassembly.
remove muffler from catalytic converter.
6.
disconnect catalytic converter air injection
piping from converter and at rubber hose
connections on feed piping on engine. remove piping
assemblies. save all clamps and hardware.
7.
disconnect oxygen sensor wire at oxygen sensor
plug (plug is located about two feet up the wire
loom).
8.
unbolt catalytic converter at converter inlet
flange. remove converter. save all hardware.
9.
remove head-pipe assembly from exhaust
manifolds.
disconnect sparkplug wires at sparkplugs. label
wires to assist in reinstallation.
remove sparkplug heat shields.
12.
disconnect egr valve feed tube from fitting at
rear of left-hand exhaust manifold and at egr
valve. a 1 1 ⁄
16
” tubing wrench may be required (snap-on,
no. rx34), and fitting may have to be heated, then
sprayed with wd40, or similar lubricant to assist in
removal from the exhaust manifold.
13.
remove exhaust manifolds from engine. unbolt
ignition coil bracket, emissions control bracket,
and dipstick tube bracket as required.
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