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

For Stinger system, proceed to
Section 3
1.
loosen the clamps holding the
air intake hose to the turbocharger
compressor inlet and the aluminum
air intake casting. remove the hose.
see Figure 2.
2.
Disengage the exhaust
backpressure control actuator rod by
sliding the cover on the end of the
rod back toward the turbocharger
and pulling the rod downward.
3.
loosen the four clamps on the
compressor discharge plenum
hoses and the clamp attaching the
plenum to the compressor. Pull the
compressor discharge plenum up off
the engine. remove the o-ring that
seals the compressor outlet to the
plenum.
4.
At the rear of the turbine housing,
remove the two bolts at the top and
the two nuts at the bottom attaching
the turbine housing to the turbine
inlet adapter. see Figure 2. save the
turbine inlet gasket for reuse.
5.
unplug the electrical connector
at the driver-side of the compressor
housing.
the turbocharger pedestal mount
must be removed with the
turbocharger. remove the four bolts
attaching the pedestal mount to
the engine block. the front two are
easily accessible. the rear two will
require the use of a swivel socket or
a universal joint-socket combination.
After these bolts have been removed,
lift the assembly off of the engine
towards the front. remove the two
o-rings located on the engine or
under the pedestal mount.
6.
Clamp the turbocharger
assembly in a vise. Do not use the
compressor inlet or outlet to clamp
the turbocharger. the compressor
housing is aluminum and could
be damaged. observe and mark
the relationship of the exhaust
backpressure control valve to the
turbine housing and the turbine
housing to the center section of the
turbo assembly.
7.
Remove the exhaust backpressure
control valve from the turbine
housing, and install it onto the new
turbine housing with the original
hardware. Duplicate the orientation
of the original assembly. use anti-
seize on the bolts.
8.
remove the four bolts securing
the turbine housing to the
turbocharger center section. if the
turbocharger is more than a few
months old, it may be necessary
to spray some liquid wrench (or
similar rust penetrating lubricant)
into the joint between the turbine
housing and the center section.
work the housing loose from the
center section by tapping with a
hammer and brass drift or a soft
face hammer. work from side to
side and use plenty of lubricant until
the housing is loose from the center
section. Pull the housing straight
off of the center section to avoid
damaging the turbine blades.
9.
Place Banks Quick-turbo ® turbine
housing onto the center section,
again paying careful attention to the
turbine blades. apply some anti-
seize to the four bolts and reinstall
them. Check the orientation of the
assembly, then tighten the bolts.
10.
make sure the gasket is on the
turbine inlet adapter on the engine.
Place the new o-rings provided into
the recesses on the engine block and
make sure that the sealing area of
the pedestal bottom is clean.
11.
reinstall the turbocharger and
pedestal assembly. make sure the
o-rings are in place before installing
any bolts. Put a small amount of
anti-seize on the turbine inlet bolts
and nuts and start them. install
and tighten the pedestal mounting
bolts then tighten the turbine inlet
bolts and nuts. Plug the electrical
connector back together.
12.
Bend the firewall lip seam as far
back as possible, on the right side
corner of the transmission tunnel, to
allow for installation of Banks two-
piece turbine outlet pipe. A 3-4 foot
piece of pipe or heavy metal bar may
be used as a lever and extended
hammer to fold and flatten the
seam against the floorpan. NOTE: If
access to a Sawzall or an air chisel is
available, a series of cuts in the seam
will ease the bending operation. It
may also be necessary to somewhat
compress and reshape the floorpan
heatshield behind the firewall lip
seam using a pipe or heavy prybar.
see Figure 3.
-EnD, SEcTIon 2-
Figure 3
96493 v.4.0
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