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

Secure the heatshield blanket provided to
the Banks turbine outlet pipe with the wire
ties provided, as shown in Figure 4 . Loosely
clamp the upper portion of the turbine outlet
pipe to the exhaust backpressure control valve
on the turbocharger. Slide the 3-inch clamp
over the end of the lower turbine outlet pipe.
Reinstall the catalytic converter in its original
position and install the lower portion of the
turbine outlet pipe between the upper pipe and
catalytic converter from underneath the vehicle.
Adjust the position of the turbine outlet pipe
to allow the maximum amount of clearance
between the pipe and the firewall. Tighten the
3-inch clamp at the pipe joint under the vehicle
and the V-band clamp at the turbine outlet.
Slide Banks Monster™ tailpipe over the
muffler outlet and install it into the original
rubber hanger. Install two 3 1 ⁄
2
-inch U-clamps over
the tailpipe at the muffler outlet connection, as
shown in Figure 5 . Note the positions of the
clamps in relation to the expanded section of
the tubing. Lightly tighten the clamps to allow
adjustment for 3 ⁄
4
- to 1-inch of clearance between
the tailpipe tip and the bottom edge of the
fender. With the tailpipe and muffler/catalytic
converter assembly properly positioned, tighten
the U-clamps at the muffler outlet and catalytic
converter inlet flange bolts. Reinstall the engine
lifting hook on the passenger-side of the engine.
For Stinger installations, proceed to Step 70.
To reconnect the exhaust backpressure
control valve, hold the cover on the end of
the rod back and have someone start the engine.
When the rod extends after a few seconds, push
it up onto the valve linkage and allow the cover to
snap back into position.
WARNING! Stay clear of moving parts such as
the engine cooling fan and belts. Do not drive
the vehicle until the remainder of the installation
is complete. Any airborne objects entering the
turbocharger may cause damage.
While the engine is running, check for oil
leaks around the base of the turbocharger
center section or the pedestal mount. Repair any
leaks before continuing. NOTE: The most likely
cause of an oil leak in this installation is a pinched
O-ring at the base of the turbocharger.
Cover the compressor inlet and discharge
with clean rags so that no foreign material
will enter the turbo during the remainder of the
installation.
For Stinger-Plus installations, proceed to Step
70.
BANKS TECHNI-COOLER INTERCOOLER
INSTALLATION
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.
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.
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.
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.
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.
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.
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.
39.
38.
37.
36.
28.
33.
32.
31.
30.
29.
35.
34.
9 P.N. 96322 v.7.0