Banks Power Ford Trucks: (Diesel ’99 - 03 7.3L Power Stroke) Forced Induction- Big Head Wastegate Actuator '99-03 F-250 & F-350 pickup - Manual (Page 4)

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 new vehicles with
exhaust leaks in this area.
Correct this condition now to
eliminate dangerous exhaust
leaks and poor turbocharger
performance.
8.
At the back side of the
turbocharger, locate the small e-clip
that retains the actuator rod end on
the wastegate arm. Using a small
screwdriver, carefully pry the clip off
of the wastegate arm and retain for
reuse. CAUTION: This clip is very
small and is easy to lose. It may
help to use a magnet to retain
the clip as you remove it. Loosen
the two wastegate actuator nuts on
the turbocharger compressor housing
and remove the actuator.
9.
Install the Banks Big Head
actuator onto the turbocharger.
Tighten the lock nuts on the
mounting studs. 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.
If the Banks Big Head wastegate
actuator was installed with the
turbocharger on the engine, proceed
to
Step 14.
10.
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 clamps
attaching the turbine housing to the
exhaust inlet casting and turbine
outlet pipe. IMPORTANT: Check
the condition of the V-band
clamps as over-tightening can
cause the clamp to spread,
allowing the T-bolt to become
loose. Replace the clamp if the
clamp is damaged or will not tighten.
11.
Reinstall the compressor
discharge plenum on the engine.
Reinstall the clamp attaching the
plenum to the turbocharger
compressor outlet and the
intercooler duct. Reinstall the four
clamps on the hoses connecting the
compressor discharge plenum casting
to the intake manifolds.
12.
Reinstall the air inlet hose to the
turbocharger compressor air inlet.
13.
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. WARNING! Stay
clear of moving parts such as
engine cooling fan and belts. Do
not drive the vehicle until the
remainder of the installation is
complete.
14.
Reconnect the boost line to the
nipple on the Banks Big Head
wastegate actuator.
15.
Reinstall the decorative plastic
engine cover.
16.
Start the engine and allow it to
warm up. Drive the vehicle, listening
for any exhaust leaks or rattles.
Adjust and tighten any clamps
removed during the installation
process if necessary.
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Gale Banks Engineering
546 Duggan Avenue • Azusa, CA 91702
(626) 969-9600 • Fax (626) 334-1743
Product Information & Sales: (800) 438-7693
Customer Support: (888) 839-5600
Installation Support: (888) 839-2700
bankspower.com