Banks Power Ford Motorhomes: (Gas ’93 - 98 7.5L Class-A) PowerPack System (Class-A, JD_OK chassis) For Use w_ 460 EFI Engine - Manual (Page 4)

4 p.n. 96347
installation instructions
remove the “dog house” cover from the
engine for access.
If a heavy-duty hoist is available, raise the
vehicle and remove the front wheels for
easier access. If the rear wheels remain on the
ground, block the rear wheels.
disconnect all cables from the battery(s).
starting from the rear of the vehicle and
working forward, remove the tail-pipe
assembly from the vehicle. leave exhaust pipe
hangers in place on the chassis. NOTE: Some joints
may require the heat from a torch to loosen them
for disassembly.
remove muffler from catalytic converter.
disconnect oxygen sensor wire at oxygen
sensor. (plug is located about two feet up
the wire loom).
disconnect catalytic converter air-injection
piping at rubber hose connections on feed
piping on engine. remove bracket bolts holding
air piping to exhaust system. save all clamps and
hardware.
unbolt catalytic converter at converter inlet
flange. remove converter with air piping
attached. save all hardware.
remove head-pipe assembly from exhaust
manifolds.
disconnect sparkplug wires at sparkplugs.
label wires to assist in reinstallation.
remove sparkplug heat shields.
disconnect egr valve feed tube from fitting at
rear of left hand exhaust manifold and at egr
valve. a 1 1 ⁄
16
” tubing wrench may be required (snap-on
no. rx34), and fitting may have to be heated, then
sprayed with Wd40, or similar lubricant to assist in
removal from the exhaust manifold.
remove exhaust manifolds from engine.
unbolt ignition coil bracket, emissions control
bracket, and dipstick tube bracket as required.
disconnect the main positive power cable
(large red cable) from the stud on the starter
motor. re-route the main power cable to the
starter motor by feeding the cable between the
side engine mount and the oil pan. cut the plastic
cable ties on the forward part of the cable bundle
as required to provide slack as needed for the new
cable routing. re-connect the cable to the starter
motor.
NOTE: Not all installations will require this. If the
battery cable does not cross over from the frame
to the starter adjacent to the exhaust manifold
area, this step may be omitted. See step 18.
inspect the cylinder head exhaust flange
surfaces. remove any loose carbon, rust, old
gasket material, etc. as required to provide a clean,
flat manifold mounting surface.
NOTE: Banks TorqueTube exhaust manifolds feature
a heavy-duty machined flange that is designed
to bolt directly against the cylinder head without
the necessity of gaskets, which are prone to
deteriorate and blow out in time. In some instances
the factory cylinder-head flange surfaces may have
become excessively eroded from leaking factory
exhaust manifolds such that the Banks manifolds
will not seal to the head. In these instances gaskets
will have to be installed between the head and
manifold to provide a seal.
put the transmission in low gear (make sure
wheels are blocked to prevent rolling). bolt
the torquetube manifolds to the cylinder heads
while noting the following items. nOTe: It may be
necessary to turn front wheels all the way to the left
to provide installation clearance.
A. four different bolt lengths are utilized. refer to
Figure 2 for bolt locations.
B. the tabs that attach the spark-plug boot
heatshields must be bent to line up with the bolt
holes in the manifold flange. adjust the tabs as
required so spark plugs may be serviced.
C. spacers are used with the bolts to mount
the dipstick tube and ignition coil bracket. The
emissions control bracket is not remounted. bend
the mounting tabs for these components to line the
tabs up with the manifold and spacer bolt holes. The
dipstick may be bent slightly as needed to clear the
manifold tube. be careful not to kink the dipstick
tube. NOTE: End tabs on some shields may not line
up with bolt holes. In this case use center-mounting
tabs only.
reconnect the egr-valve exhaust feed tube
to the egr valve, then to the bung on the
left-hand TorqueTube manifold. feed tube may be
bent slightly if needed. a light lubricant or anti-
sieze on the threads eases installation.
check that the positive battery cable to
the starter motor has at least 3 inches of
clearance to any part of the TorqueTubes. also
check that the cable will not rub on any sharp
edges that could cut through the insulation and
cause a short. reposition or tie the cable in place
to correct any of these conditions.
18.
17.
16.
15.
14.
13.
12.
11.
9.
10.
8.
7.
6.
5.
4.
3.
1.
2.