Banks Power Ford Trucks: (Diesel ’03 - 07 6.0L Power Stroke) Exhaust- Monster Sport Exhaust System 2003-07 Ford 6.0L Ecsb - Manual (Page 8)

1.
Disconnect the negative
(ground) cable from the battery (if
there is more than one battery,
disconnect both negative cables).
Secure the cable so it cannot
accidentally come in contact with the
post.
2.
Raise the vehicle and support it
securely with properly weight-rated
safety stands, ramps or a commercial
hoist. Take care to balance the vehicle
to prevent it from slipping or falling.
When using ramps, be sure the
wheels are centered squarely on the
topsides. Place the transmission in park
(automatic) or reverse (manual), set
the parking brake and securely block
the wheels that are on the ground.
CAUTION: Do not work under any
vehicle supported only by a jack.
Severe injury may result.
WARNING! The following step
may require the use of a torch and/
or saw. Proper safety equipment
should be used. Failure to use
proper safety equipment may
result in severe injury.
3.
From under the vehicle, remove
the factory exhaust system from the
catalytic converter back. Starting at
the rear of the vehicle, remove each
component by either cutting through
the pipe near the clamps or by
removing the clamps and heating the
joints with an Oxy-Acetylene torch
to allow crimped pipes to separate.
DO NOT cUT OR DAMAGE cATALYTIc
cONVERTER TUBING DURING THE
REMOVAL PROcESS. Remove the
hanger pins from the rubber hangers
with a pry bar. (Spray lubricant will ease
hanger removal.)
5.
Place a supplied 3 1 ⁄
2
” clamp
onto the front of the supplied
intermediate pipe.
6.
Install the supplied intermediate pipe
onto the catalytic converter outlet. Be
sure the notch and catalytic converter
pin are properly aligned. Lightly snug
the 3 1 ⁄
2
” clamp onto the front of the
intermediate pipe / catalytic converter
outlet.
For crew-cab long-bed models, install
the supplied extension pipe onto the
intermediate pipe and snug a supplied
4” clamp onto the connection.
Note: Exhaust clamps should be
placed at the beginning of the slot and
evenly tightened.
7.
For crew-cab long-bed, extended-cab
short bed, and extended-cab long-bed
models, it is necessary to relocate the
factory-installed frame-mounted hanger
pin that is located behind the rear
transmission crossmember.
A) Remove the two (2) factory nuts that
mount the front muffler hanger pin to
the frame rail and remove the hanger
pin from the vehicle.
Note: Extended cab short bed
models will NOT use the two (2) 3 ⁄
8
”
spacers.
B) Re-install the frame mounted hanger
pin using the two (2) 3 ⁄
8
” long steel
spacers onto the factory exhaust
hanger studs. Install the hanger/spacer
assembly into the vehicle frame holes
about 10-16” to the rear of the original
muffler hanger location (see Figure 2).
Note: Spacers are to be installed
between the hanger pin and the inside of
the frame rail. Torque factory nuts to
20 ft-lbs.
Monster Exhaust System Installation
8
96571 v.2.0