Banks Power Ford Trucks: (Diesel ’94 - 97 7.3L Power Stroke) Power Systems- PowerPack, Stinger-Plus & Stinger '94-98 3-1_2

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.
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.
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.
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.
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 .
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 .
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.
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 .
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.
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.
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.
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.
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.
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.
1 0 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.
Check the clearance between the intercooler
hose connections and the surrounding
sheet-metal below and on the outer sides of the
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10 P.N. 96322 v.7.0