Banks Power Ford Trucks: (Diesel ’99 - 03 7.3L Power Stroke) Power Systems- PowerPack, Stinger-Plus, Stinger & Git-Kit '19991_2-2003 F-250 & F-350 Trucks and Excursions - Manual (Page 10)

10
96336 v.10.0
1.
For 2002-03 models only, it is
necessary to relocate the factory-
installed frame-mounted hanger pin
that is located behind the transmission
crossmember.
A. Remove the two (2) nuts that hold
the frame-mounted hanger pin to the
frame rail, save for reinstallation later.
Remove the frame-mounted hanger
pin from vehicle.
B. Remove the two (2) 8mm studs from
the frame-mount hanger pin.
NOTE: Studs are pressed into hanger
pin and will require the use of a
hammer or small press to remove.
C. Reinstall the frame-mounted hanger
pin using the two (2) 5 ⁄
8
” long steel
spacers, two (2) 8mm x 1.25 x
45mm bolts and the two (2) 8mm
nuts (removed in Step A above).
See Figure 3 for proper assembly
sequence. Torque fasteners to 18 ft-lb.
2.
Reusing the saved V-band clamp
previously put aside, loosely clamp
the upper portion of the turbine outlet
pipe to the warm-up valve or the Banks
Brake on the turbocharger. Do not
tighten at this time.
NOTE: On some Power Strokes a ground
strap is bolted on back of the cylinder
head. This bolt may interfere with the
Banks turbine outlet pipe. If so, remove
the bolt and relocate it in the cylinder
head.
3.
Place a 4” exhaust clamp on the
turbine outlet pipe. Install the front
intermediate pipe onto the turbine
outlet pipe. Place a 4” exhaust clamp on
the front intermediate pipe (see Figure
5).
For vehicles with a catalytic
converter: Place a 4” exhaust clamp on
the turbine outlet pipe. Install the front
intermediate pipe onto the T.O.P., aligning
the hanger pin in the rubber hanger.
Put a 3 1 ⁄
2
” clamp on the end of the
front intermediate pipe and reinstall the
catalytic converter (where you have cut
per step 3-4). Put another 3 1 ⁄
2
” clamp on
the outlet of the catalytic converter (see
Figure 5).
4.
For Standard Cab long-bed
vehicles: It will be necessary to cut
4 3 ⁄
4
” off the rear intermediate pipe
supplied in the kit. The hanger will be
removed with the unused portion of
the pipe (see Figure 4). Install the rear
intermediate pipe.
For Excursions and Super-cab short-
bed: Install the rear intermediate pipe
as supplied (no cut required).
For Crew-cab short-bed: Install the
rear intermediate pipe. Place a 4” clamp
on the end of the rear intermediate
pipe and install the extension pipe (P/N
53513).
For Super-cab long-bed: Remove the
rear frame mounted hanger and install
the supplied frame mounted hanger in
its place, using the two 8mm x 30mm
hex bolts supplied and re-using the
two 8mm nuts previously removed (see
Figure 6). Install the rear intermediate
pipe. Place a 4” clamp on the end of the
rear intermediate pipe and install the
extension pipe (P/N 53514).
For Crew-cab long-bed: Install the rear
intermediate pipe. Place a 4” clamp on
the end of the ear intermediate pipe and
install the extension pipe (P/N 53515).
5.
Place the front hanger clamp on the
inlet end of the Banks Monster muffler
and install it onto the intermediate
pipe or extension pipe. Note the inlet
labeling on the Monster muffler. Be sure
the Banks Monster embossing on the
muffler is level with the frame.
Insert the front hanger pin into the
rubber hanger at the front of the
muffler.
6.
For trucks, slide the rear hanger
clamp over the outlet of the muffler with
the hanger pins facing forward. Insert
the hanger pin(s) into the corresponding
rubber hanger(s).
Section 6
MoNSTER ® EXHAuST INSTALLATIoN (PART 2 oF 2)
Figure 3- Proper Frame Mounted Hanger Assembly Sequence