Banks Power Dodge Trucks: (Diesel ’03 - 07 5.9L Cummins) PowerPack & Stinger w_EconoMind '06-07 For use with PowerPDA User Manual

Page 8

96813 v.9.0

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.

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.

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.

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.

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

⁄

” away from its original position.

Step 7 thru 11 for single exhaust

Step 12 thru 23 for split dual
Single exhaust

Install a 4” exhaust clamp on the

muffler outlet. Adjust the hanger

clamp to a position that best supports

the muffler.

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.

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 (+/-

⁄

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