Banks Power Ford Motorhomes: (Gas ’97 - 04 6.8L Class-C) Power Systems- PowerPack & Stinger Systems & Optional OttoMind (Class-C) - Manual (Page 7)

Section 1
TORQUETUBE MANIFOLDS
Power Pack Installation
For Stinger installation, proceed to
step 27.
1.
Locate the oxygen sensors in each
exhaust headpipe, downstream of
the factory exhaust manifolds. Unplug
the connectors and remove both the
oxygen sensors. Mark the sensors for
correct reinstallation.
2.
Locate the oxygen sensor
downstream of the catalytic converter.
This sensor should be unplugged, but
does not need to be removed from the
pipe.
3.
Disconnect the catalytic converter
from the factory Y-pipe.
E-350 models - Remove the three
(3) nuts from the factory catalytic
converter flange, retain the nuts for
reuse.
E-Super Duty or E-450 models -
Some models are equipped with either
a slip joint catalytic converter or three
(3) bolt flange. If equipped with a slip
joint converter remove the clamp
between the factory Y-pipe assembly
and catalytic converter. If vehicle
is equip with a three (3) bolt flange
catalytic converter remove the three
(3) nuts from the factory catalytic
converter flange, retain the nuts for
reuse.
4.
Disconnect the headpipes from the
exhaust manifolds and remove the
Y-pipe assembly from the vehicle.
5.
On the driver’s side of the engine,
unscrew the EGR tube from the
exhaust manifold with a 1 1 ⁄
4
” wrench
and remove the EGR tube from the
manifold.
6.
Pull out the dipstick and remove
the small bolt that attaches the oil
pan dipstick tube to the cylinder head.
At the front of the engine, locate and
loosen the nut that retains the dipstick
tube bracket. Pull the dipstick tube
up out of the engine block. check to
see if there is an O-ring on the tube.
If not, the O-ring may be stuck inside
the hole in the engine block. This
O-ring should be retrieved if necessary
and placed back onto the tube before
reinstalling it.
7.
To remove the exhaust manifolds,
use a wrench or socket to back the
nuts away from the manifolds at least
one turn, then use a 5mm 6 point
socket to remove each stud from
the head. As an alternate method,
take the nuts off the studs, and then
remove the studs.
8.
After the manifolds have been
removed from the vehicle, remove
any remaining studs from the heads.
The studs must be removed from the
heads in order to install the Banks
TorqueTubes.
9.
Remove the large EGR adapter
fitting from the left side factory
manifold and install it onto the left
Banks TorqueTube manifold. Reuse the
original copper washer if equipped,
between the manifold and adapter.
Use anti-seize on the threads to
prevent galling.
10.
On both sides of the vehicle, the
exhaust heat shielding will need to be
repositioned to allow the PowerPack
components to be installed. Remove
the bolt at the front of each heat
shield and loosen the bolts at the rear
on the cross member. Reattach each
heat shield at the front using two
8mm bolts and 5 ⁄
8
” spacers provided.
Retighten the two bolts at the rear of
both heat shields.
96401 v.9.0
7