Banks Power Dodge Trucks: (Diesel ’03 - 07 5.9L Cummins) PowerPack & Stinger w_EconoMind '03-05 For use with PowerPDA User Manual

Page 8

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.

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.

From under the vehicle remove

the factory exhaust system. Starting

at the rear of the vehicle, remove tail

pipe, muffler and any extension pipes

attached to the outlet of the catalytic

converter, 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. Remove the

hanger pins from the rubber hangers

with a pry bar. (Spray lubricant will

ease hanger removal.)
Steps 4 thru 10 for 2003-2004

Step 11 for 2005

Remove the clamp attaching

the turbine outlet pipe (T.O.P) to

the catalytic converter headpipe

(or intermediate pipe if applicable)

and remove the catalytic converter

assembly or intermediate pipe.

Remove the V-band clamp that

attaches the turbine outlet elbow to

the turbine housing and remove the

turbine outlet pipe and elbow from

the vehicle.

Attach the supplied T.O.P. gasket

to the Banks T.O.P. Loosely place

the supplied V-band clamp on the

Banks T.O.P. Install the Banks T.O.P.

to the turbine housing (note: the

factory turbine outlet elbow will not

be used). Loosely snug the V-band

clamp assuring the gasket and T.O.P

are aligned properly.

For vehicles that are NOT

equipped with a catalytic converter,

install the supplied Banks front

intermediate pipe and supplied

gasket onto the previously installed

Banks T.O.P. Place a small amount

of anti-seize onto the four (4)

⁄

”

bolts. Loosely install the supplied

⁄

” hardware onto the T.O.P. and

intermediate pipe flange (see Figure

1). Proceed to Step 10.

For vehicles equipped with

catalytic converters: With the

catalytic converter removed from the

vehicle and the headpipe removed

from the converter, measure 13”

inward from the outlet tubing rim

(3-

⁄

” of tubing from the outlet weld

should remain). Using a reciprocating

saw or equivalent, vertically cut and

remove 13” from the converter outlet

tubing (see Figure 2).

Install the supplied 3-

⁄

” clamp

onto the catalytic converter inlet.

Place the catalytic converter onto

the previously installed intermediate

pipe. Loosely snug the clamp on the

catalytic converter inlet.
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 gridwork 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 gridwork. If your catalytic

converter is damaged, it may

be covered under your vehicle’s

emissions warranty.

10.

Place a supplied 4” clamp

onto the front of the supplied

rear intermediate pipe. Install the

intermediate pipe onto the catalytic

converter outlet or the front

intermediate pipe. Lightly snug the

exhaust clamp near the rim of the

intermediate pipe.

11.

2005 NOTE: The catalytic

converter will not be removed

from the vehicle. Remove attached

intermediate pipe and corresponding

clamp(s). Take care not to damage

the catalytic converter outlet end.
Step 12 thru 20 for Single Tip

Step 21 thru 33 for Split Dual

12.

2003-2004 For quad cab long

bed (160.5” wheelbase) models only:

Place a supplied 4” clamp onto the

front of the supplied extension pipe.

Install the extension pipe hanger

pin into the corresponding rubber

hanger. Connect the extension pipe

onto the intermediate pipe and

loosely snug the 4” clamp.

13.

For Crew Cab Long Bed (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.

Figure 2

96812 v.7.0