Banks Power Ford Trucks: (Diesel ’99 - 03 7.3L Power Stroke) Power Systems- Stinger, Stinger-Plus & PowerPack systems '19991_2-2003 F250_F350 Trucks & Excursion (non-cat) - Manual (Page 12)

31.
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.)
32.
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.
33.
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.
34.
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.
35.
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.
36.
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.
37.
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.
38.
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.
39.
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.
40.
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.
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.
41.
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.
42.
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.
43.
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.
44.
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 side of
the clamp. Reinstall the bracket using
a #56 hose clamp provided to secure
the filter/dryer unit to the bracket.
Section 5
BANKS TECHNI-COOLER ® INSTALLATION
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