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 14)

14
96336 v.10.0
For Git-Kit installation, proceed
to Section 9 .
For Stinger installation, proceed
to Section 8 .
For Stinger-Plus installation, proceed to
Step 23 .
For PowerPack installation, continue
with Step 1 .
1.
Remove the factory intercooler
plumbing from the vehicle. Loosen the
clamps on the boost tubes and remove
the boost tubes. (It is assumed that the
compressor discharge plenum casting has
been removed from the vehicle at this
point.)
2.
To remove the factory intercooler, it
will be necessary to remove the grille
assembly. At the front of the vehicle,
remove the pushpins holding the rubber
air deflector to the grille support and
remove the air deflector. Remove the
screws at the top of the grille, dis-connect
the lower clips with a small screwdriver,
and remove the grille.
3.
On each side, remove the bulb from
the headlight assembly. Remove the two
bolts below the turn signal/marker light
combination and remove the assembly
by pulling it directly forward. Remove the
bulbs from the turn signal/marker lights or
disconnect the connectors to separate it
from the vehicle.
4.
Remove the pushpin and the hood
cable clip to disconnect the left air
deflector from the radiator core support.
Separate the left air deflector from the
grille support by removing the pushpins
from the bracket on the grille support.
Repeat this process for the right side air-
deflector, removing the pushpins from the
core support and grille support.
5.
Remove the upper a/c condenser
brackets. Remove the grille support
bracket attaching bolts and remove the
grille support from the vehicle. The a/c
condenser needs to be lifted at the same
time as the grille support is pulled away
from the vehicle. Pull from the bottom
at first to pivot the support upwards as
you pull forward. The a/c condenser will
fit between the air deflector brackets as
the support moves forward. Be cautious
of the corners of the front fenders as the
condenser is lifted up. It may be beneficial
to cover the fender corners with masking
tape or some other form of protection.
6.
Scribe a line around the hood latch
with a sharp instrument to mark the
location of the latch, then remove the
latch from the upper radiator support. Do
not remove the cable from the latch. Move
the latch out of the way.
7.
Remove the jacking tools from the core
support and remove the coolant reservoir
bolt from the jacking tool mount bracket.
Remove the upper radiator brackets.
Remove the upper diagonal brace bolts
from the upper radiator core support.
Remove the wiring harness from the
intercooler mounting studs and remove
the studs from the upper radiator support.
Remove the six bolts on each end of the
upper radiator core support cross bar and
remove the upper core support cross bar
from the vehicle. It may be necessary to
pry the cross bar up out of the slot in the
core support.
8.
Pull the air conditioning condenser up
out of the lower brackets and swing it up
over the engine and out of the way. Be
careful of the tubes that carry pressurized
refrigerant. Do not bend the tubes as they
are aluminum, and can be easily damaged.
Using a bungee cord or similar equipment,
temporarily suspend the condenser from
the hood of the vehicle, out of the way.
9.
Remove the bolt attaching the power
steering cooler to the diagonal brace.
Remove the diagonal braces from the
lower radiator core support. Tilt the
intercooler forward and remove it up and
out of the vehicle.
NOTE: Later models do not have
diagonal braces, unbolt power-steering
cooler from brackets as required.
10.
Using the four 1 ⁄
4
”-28 x 2” bolts,
washers and nylock nuts, loosely bolt
the new lower intercooler mounting
brackets to the lower mounting crossbar.
Position this mounting assembly into the
vehicle as shown in Figure 5. Using the
lower diagonal brace mounting holes as
locations, position the crossbar assembly
level in the vehicle and temporarily bolt
the brackets to the core support using the
lower diagonal brace bolts.
Using the brackets as a template, mark
the four holes necessary to complete the
attaching of the lower mounting brackets,
and drill four 1 ⁄
8
” holes in those positions.
Attach the lower mounting brackets to
these holes in the core support with the
four #10 sheet metal screws provided.
Now remove the two factory diagonal
brace bolts.
NOTE: On later model vehicles without
diagonal braces and associated
bolt holes, slide the lower intercooler
mounting crossbar, with brackets loosely
attached, up the sides of the core
support opening until the brackets come
against the bottom edges for the “ears”
that overlap the inside edge of the core
support opening. If the lower intercooler
mounting brackets cannot be slid out far
enough on the crossbar to contact the
sides of the core support opening at this
elevation, slide each bracket outward
on the crossbar as far as it will go, then
tighten the 1 ⁄
4
” thru-bolts, set the crossbar
assembly in the core support opening, and
level it to the vehicle.
With the crossbar assembly positioned
in the core support opening as indicated,
scribe the core support through the four
holes on the inside edges of the brackets,
being certain that the front flanges of the
brackets (with the single unused bolt hole)
are against the face of the core support.
Drill four 1 ⁄
8
” holes at the scribed locations,
then attach the brackets to the core
support with four #10 sheet metal screws
provided.
11.
Remove the rubber air deflector strips
from the ends of the factory intercooler by
snipping the plastic ties that run through
the intercooler fins. Attach the deflectors
to the inboard side of the 3-hole tabs on
the Banks intercooler by installing one 1 ⁄
4
-
28 x 1” hex bolt, washer, and nylock nut
assembly through the bottom hole on the
lower tab on each end of the intercooler
and the existing bottom hole on each
deflector strip. The remaining three holes
on the deflector strips will not line up with
the holes in the intercooler. Drill or punch
a new set of holes in the deflector strips
to line up with the upper holes in the
lower tabs on the intercooler, then install
a 1 ⁄
4
-28 x 1” hex bolt, washer, and nylock
nut assembly in each of these locations.
(See Figure 5) Drill or punch a third set of
holes through each deflector strip to line
up with the middle hole in the upper tabs
on the intercooler.
12.
Loosely bolt the upper brackets to
the Banks Techni-Cooler as shown in
Figure 5 using four 1 ⁄
4
-28 x 1” hex bolts,
1 ⁄
4
” washers and nylock nuts through the
outboard holes in the two upper tabs on
the intercooler.
13.
Trim the rubber air deflector to clear
the upper bracket attaching nuts so the
deflector will sit flat against the tab on
the intercooler. Attach the deflectors to
the intercooler at the middle hole in each
upper tab using another pair of 1 ⁄
4
”-28 bolt
assemblies. Do not tighten these bolts yet.
14.
On the passenger side of the engine
compartment, locate the air conditioning
filter/dryer assembly. It will be necessary
to modify the clamping bracket to allow
clearance for the new tube assembly.
Remove the upper filter dryer bracket by
unbolting in three places. Using a hacksaw
or other cutting tool cut the forward half
of the clamp off in front of the elevated
tab across from the opening of the clamp.
Next cut the remaining tab off of the open
Section 7
BANKS TECHNI-CooLER ® INSTALLATIoN