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

For Stinger and Stinger Plus
systems, proceed to Section 5
1.
Cover the compressor inlet and
discharge with clean rags so that
no foreign material will enter the
turbo during the remainder of the
installation.
2.
remove the grille. there are four
Phillips-head screws across the top
and two in the center of the grille
that secure it to the grille support.
3.
Remove the headlight bezels.
these are secured to the grille
support with two screws across
the top and two nuts behind the
radiator core support. the two nuts
are accessed by reaching down
between the battery and the radiator
core support. the batteries may be
removed for easier access to the
hardware. When each bezel is loose,
pull it gently away from the front
of the truck. label and remove the
signal and running light bulbs from
the rear of the bezel.
4.
remove the narrow front valance.
it is attached to the front of the
truck by four small bolts which
may be reached through the front
of each wheelwell and three small
bolts across the front. remove the
two front bolts attaching the inner
wheelwell to the fender and pull it
back towards the rear of the vehicle.
the bolts can then be reached with
a socket and extension. The plastic
filler panel is attached to the fenders
at the front with plastic clips that
must be pried out of the holes in the
fenders. a door-panel-clip removal
tool works well for this.
5.
the plastic grille support must
now be removed. Push the dangling
parking and signal light bulbs
through the holes into the engine
compartment to get them out of the
way. remove the headlight bulbs
with sockets from the rear of the
headlight reflectors. Do not remove
the headlight reflectors from the
plastic grille support. avoid touching
the headlight bulbs themselves. if
necessary, wipe bulbs clean with
alcohol.
6.
remove the eight bolts attaching
the plastic grille opening panel to the
radiator core support. there are two
on each side at the extreme outer
edge of the panel and two on each
of the brackets inside the radiator
opening. Do not remove the sheet-
metal brackets from the vehicle.
7.
on automatic transmission-
equipped models, unbolt the
transmission-fluid cooler from the
passenger-side of the radiator
opening. remove the mounting
brackets and clamps from the cooler.
it is not necessary to disconnect the
hoses.
8.
remove the template pages from
this manual. line up the templates
with the bolt-holes and edges of the
radiator core support. mark the core
support and cut away the areas of
sheet-metal shown in Figures 6
and 7 at the back of this manual. a
reciprocating saw such as a Sawzall
with a fine tooth blade works best
for this, however a hole saw in a
drill motor may be used to make a
set of overlapping holes that may
be ground or filed to make the final
shape. De-burr the cut edges once
cutting is complete. it is suggested
that the raw edges be painted with a
rust-preventative primer or paint.
9.
Pry out and remove the four
plastic buttons holding the outer
corners of the rubber air-dam to the
radiator core support as shown in
Figure 8. remove the buttons from
the air-dam.
10.
install the left and right lower
intercooler mounting brackets and
nut plate assemblies using four 1 ⁄ 4
x 3 ⁄ 4 -inch hex bolts and washers
through the holes in the core
support as shown in Figure 8. leave
the bolts just loose enough to slide
the brackets for adjustment.
11.
on all models install the two
transmission-fluid cooler mounting
brackets provided, as shown in
Figure 9. these brackets mount
over the factory studs in the core
support between the air-conditioning
condenser brackets and the core
support. if the vehicle does not have
air-conditioning, install two 8 mm
x 1.25 mm nuts provided over the
studs with two 5 ⁄ 16 flat washers.
12.
on automatic transmission
models only, install two rubber lined
loop clamps onto the transmission-
fluid cooler as shown in Figure 9.
mount the cooler to the brackets
using the two 1 ⁄ 4 x 3 ⁄ 4 -inch bolts, two
washers, and two nylock nuts. Route
the hoses as shown in Figure 9.
13.
on vehicles with a front sway-
bar crossing under and just ahead
of the radiator area, unbolt the two
sway-bar bushings from the bottom
of the frame rails. reinstall the
bar and bushings using the 2-inch
square spacers, four 3 ⁄ 8 x 3 1 ⁄ 4 -inch
hex bolts, washers, and nylock nuts
provided. see Figure 10.
14.
Cut a slit in each side of the
factory rubber air-dam as shown in
Figure 9. slide the slit over the edge
of each lower intercooler mounting
bracket as shown. mark through
the two holes on the forward facing
tabs on the transmission-fluid cooler
mounting brackets onto the rubber
air-dam. Drill a 1 ⁄ 4 -inch hole through
the rubber at these two locations.
Bolt the factory air-dam to the
transmission-fluid cooler brackets
using two 1 ⁄ 4 x 3 ⁄ 4 -inch hex bolts,
washers, and nylock nuts provided.
15.
install two rubber air-dams
provided onto the drilled tabs on the
intercooler end tanks. use four #10-
32 screws, washers, and nylock nuts
to attach each air-dam. see Figure
11.
16.
install two 5 ⁄ 16 -inch studs into
the lower front threaded holes in
the end tanks. slide a rubber isolator
bushing onto each of the studs. see
Figure 8
17.
lower Banks techni-Cooler ™
intercooler into position behind
the bumper brackets on the frame.
make sure the plastic bumper stud
assemblies are in place with the
studs pointing forward. see Figure
12. one end of the intercooler may
have to be tilted down to guide the
hose connections through the holes
cut in the radiator core support.
it may also be necessary to back
out one or more radiator mounting
bolts as these can get hung up
while lowering the intercooler
into position. Guide the studs with
the rubber isolators into the slots
on the lower mounting brackets.
if the vehicle has an automatic
transmission, route the transmission-
fluid lines above the intercooler
hose connection rather than below
it to position the lines away from
sharp edges. tuck the air-dam flaps
inside the radiator opening in the
core support. Check the clearance
of the cut edges to the sides of the
intercooler end tanks. remove the
techni-Cooler and trim the sheet-
metal again if necessary.
Section 4
BANKS TECHNI-COOLER INTERCOOLER INSTALLATION
96493 v.4.0
9