Banks Power Ford Trucks: (Diesel ’94 - 97 7.3L Power Stroke) Power Systems- PowerPack, Stinger-Plus & Stinger '94-98 4

18.
adjust the techni-Cooler side-to-
side position to provide an identical
distance between the intercooler
hose connections and the sides of
the radiator. once this location has
been established, push each lower
mounting bracket away from the
center of the vehicle and tighten the
upper two bracket bolts, then the
lower two bolts.
19.
install two rubber isolator stud
mounts through the existing holes in
the radiator core support. See Figure
8. secure the mounts using the
5⁄16-inch nylock nuts and washers as
shown.
Note: that a washer is placed
between each mount and the core
support as well as under the nuts.
Leave the nuts just loose enough to
allow positioning of the mounts.
20.
install left and right upper
intercooler mounting brackets
between the rubber stud mounts and
the intercooler end tanks. thread
four 5 ⁄ 16 x 3 ⁄ 4 -inch hex bolts and
washers through the bracket and into
the threaded holes in the end tank
finger tight. install and tighten a
5 ⁄ 16 -inch nylock nut and washer
onto each stud mount to secure the
brackets.
21.
again check the side to side
position of the intercooler hose
connections with respect to the
radiator, then remove and reinstall
each of the 5 ⁄ 16 -inch hex bolts one at
a time with a drop of thread-locker,
supplied, on the threads. Tighten
the two 5 ⁄ 16 -inch nylock nuts on the
rubber stud mounts behind the core
support.
22.
Check to see that the rubber
air-dam flaps rest flush against the
sheet-metal without preventing the
intercooler from resting in its proper
location. Due to factory tolerances, it
may be necessary to trim the air-dam
flaps for proper fit.
23.
Check the clearance between
the intercooler hose connections
and the surrounding sheet-metal
below and on the outer sides
of the hose connections. there
should be a minimum of 5 ⁄ 16 -inch
clearance around the connection
to accommodate the thickness of
the hose and clamp. if additional
trimming to the sheet-metal is
necessary, remove the intercooler by
removing the upper brackets from
the rubber isolator studs. remember
to have the bumper stud plates and
the transmission-fluid cooler lines in
the proper places when reinstalling
the intercooler.
NOTE: Before slipping any boost
tubes and the corresponding
hoses, into position, ensure that all
connection ends are clean and free
of any oil residue and contaminates.
Clean compressor outlet and all
connection points with a non-oil
based solvent such as Acetone,
Mineral Spirits, Denatured Alcohol or
Lacquer Thinner. Read and follow the
manufactures operation instruction
for non-oil based solvent cleaner.
24.
with the intercooler bolted in
place, push a 3 x 3-inch silicone
hose onto each intercooler hose
connection until the hose bottoms
against the stop on the connection.
Slide a pair of #313 T-bolt clamps
onto each hose. Position the clamps
so that they can be tightened from
above.
Figure 10
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96493 v.4.0