Monster exhaust system installation – Banks Power Ford Trucks: (Diesel ’03 - 07 6.0L Power Stroke) Exhaust- Monster Exhaust, Single Passenger side exit, F-250_F-350 '03-07 Pickup Trucks and Excursions User Manual

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Disconnect the negative

(ground) cable from the battery (if

there is more than one battery,

disconnect both negative cables).

Secure the cable so it cannot

accidentally come in contact with the

post.

Raise the vehicle and support it

securely with properly weight-rated

safety stands, ramps or a commercial

hoist. Take care to balance the vehicle

to prevent it from slipping or falling.

When using ramps, be sure the

wheels are centered squarely on the

topsides. Place the transmission in park

(automatic) or reverse (manual), set

the parking brake and securely block

the wheels that are on the ground.

CAUTION: Do not work under any

vehicle supported only by a jack.

Severe injury may result.
WARNING! The following step

may require 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.

From under the vehicle, remove

the factory exhaust system from the

catalytic converter back. Starting at

the rear of the vehicle, remove each

component by either cutting through

the pipe near the clamps or by

removing the clamps and heating the

joints with an Oxy-Acetylene torch

to allow crimped pipes to separate.

DO NOT cUT OR DAMAGE cATALYTIc

cONVERTER TUBING DURING THE

REMOVAL PROcESS. To assist in

removal, the turbine outlet pipe (T.O.P.)

should be cut before the transmission

if it is going to be replaced. Remove

the hanger pins from the rubber

hangers with a pry bar. (Spray lubricant

will ease hanger removal.)

Remove the two (2) nuts attaching

the T.O.P. to the catalytic converter

inlet. Loosen and remove the

band clamp that attaches the rear

intermediate pipe to the catalytic

converter outlet. Remove

the catalytic converter assembly

from the vehicle. Remove the band-

clamp that attaches the T.O.P. to the

turbocharger and remove the factory

T.O.P. from the vehicle. Retain V-band

clamp for re-assembly.
Note: To assist in T.O.P. removal,

remove the rear engine hoist hook by

removing the two (2) Hex screws and

remove the valve cover heatshield.

The dipstick tube may also be

removed or slightly bent to allow for

T.O.P. removal/installation. Retain all

hardware and parts for reassembly.
For Manual Transmissions only: The

transmission will need to be lowered

to allow for removal and installation of

the T.O.P. Using a transmission jack,

support the rear of the transmission to

allow working room for the T.O.P. and

remove the rear transmission mount

and crossmember. Remove the Front

drive shaft support bracket from the

cab. Lower the transmission 4-6” and

remove the factory T.O.P.
The transmission may need to be

raised before the Banks T.O.P. is

installed. Install the Banks T.O.P.

Raise the transmission and reinstall

drive shaft bracket, transmission

crossmember and rear transmission

mount. Refer to vehicles owners manual

for factory Torque Specifications.

Loosely place the factory V-band

clamp on the Banks T.O.P. Install the

Banks T.O.P. to the turbine housing.

Loosely snug the V-band clamp

assuring the T.O.P. is aligned properly.
Note: Reinstall the engine hoist hook

and valve cover heat shield if

previously removed.

Monster Exhaust System Installation

96440 v.13.0