Banks Power Ford Trucks: (Diesel ’03 - 07 6.0L Power Stroke) Power Systems- PowerPack & Stinger w EconoMind ('03-07) Compatible w_ Optional PowerPDA User Manual

Page 12

96811 v.10.0

Exhaust System Installation
Use the Bill of Materials chart and

Figure 1a or 1b reference component

nomenclature and location. Use

caution when working in the engine

compartment. Make sure the engine

has been off for several hours and is

cool.

Disconnect the battery ground

cables from each of the batteries.

Secure the cables so that they do

not come in contact with the battery

posts.

Remove the (+) battery cable from

the driver side battery.

Remove the driver side plastic

battery cover. This is accomplished by

depressing a tab at the front and rear

of the cover. Be careful not to damage

the cover, as it will be re-installed.

Remove the driver side battery hold

down clamp (8mm socket).

Remove the driver side battery.

WARNING: When lifting a battery,

excessive pressure on the end

walls could cause acid to spew

through the vent caps, resulting

in personal injury. Lift with a

battery carrier or with hands

on opposite corners. Failure to

follow these instructions may

result in personal injury.

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.

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 oxyacetylene torch

to allow crimped pipes to separate.

DO NOT cUT OR DAMAGE cATALYTIc

cONVERTER TUBING DURING THE

REMOVAL PROcESS. To assist in

removal, the T.O.P. should be cut

before the transmission if it is going to

be replaced. Remove the hanger pins

from the rubber hangers with a pry

bar. (Spray lubricant will ease hanger

removal.)

Remove the two (2) nuts attaching

the turbine outlet pipe (T.O.P.) to the

catalytic converter inlet. Loosen and

remove the band clamp that attaches

the rear intermediate pipe to the

catalytic converter outlet. Remove

the catalytic converter assembly

from the vehicle. Remove the v-band-

clamp that attaches the T.O.P. to the

turbocharger and remove the factory

T.O.P. from the vehicle. Retain V-band

clamp for re-assembly.
Note: To assist in T.O.P. removal,

remove the rear engine hoist hook

by removing the two (2) Hex screws

and remove the valve cover heat

shield. The dipstick tube may also be

removed or slightly bent to allow for

T.O.P. removal/installation. Retain all

hardware and parts for reassembly.

For Manual Transmissions

only: The transmission will need

to be lowered to allow for removal

and installation of the T.O.P. Using a

Transmission Jack, support the rear

of the transmission to allow working

room for the T.O.P. and remove the

rear transmission mount and cross

member. Remove the Front drive shaft

support bracket from the cab. Lower

the transmission 4-6” and remove

the factory T.O.P. The transmission

may need to be raised before the

Banks T.O.P. is installed. Install the

Banks T.O.P. Raise the transmission

and reinstall drive shaft bracket,

transmission cross member and rear

transmission mount. Refer to vehicles

owners manual for factory Torque

Specifications.

10.

Loosely place the factory V-band

clamp on the Banks T.O.P. Install the

Banks T.O.P. to the turbine housing.

Loosely snug the V-band clamp

assuring the T.O.P. is aligned properly.
Note: Reinstall the engine hoist

hook and valve cover heat shield if

previously removed.

11.

The catalytic converter inlet will

need to be trimmed to accommodate

the Banks exhaust system. Be careful

not to trim an excessive amount of

tubing. Be sure to wear proper safety

equipment.
IMPORTANT: Diesel catalysts

may become plugged with soot,

which can restrict exhaust flow,

impeding performance. Inspect

the converter by shining a

powerful flashlight into the inlet.

Observe the light through the

other end of the converter. The

full circle of the flashlight should

be visible without any blockage

in the grid work of the catalyst.

If excessive soot is observed,

the catalyst may need to be

cleaned. TAkE PRECAuTIONS to

avoid blowing soot toward the

work area or where it could be

inhaled. ALWAyS use breathing

protection. Also inspect the

catalyst for damage (i.e. chips,

bent corners, etc.) to the grid

work. If your catalytic converter

is damaged, it may be covered

under your vehicle’s emissions

warranty.

12.

With the catalytic converter

removed from the vehicle and the

head pipe removed from the converter,

measure approximately 4” from the

weld and mark the location (this

location should be before any bend,

about 7” rear of the inlet flange). Using

a reciprocating saw or equivalent,

vertically cut and remove 7” from the

converter inlet tubing. Make sure cut is

square (see Figure 2).

13.

Install the supplied Banks front

intermediate pipe onto the previously

installed Banks T.O.P. Loosely install

a supplied 4” exhaust clamp onto the

forward end of the front intermediate

pipe.

14.

Install the supplied 3

⁄

”

clamp onto the outlet of the front

intermediate pipe. Place the trimmed

catalytic converter onto the previously

installed front intermediate pipe. Be

sure the notch and catalytic converter

pin are properly aligned. Snug the

clamp onto the catalytic converter

inlet, but do not tighten at this time.

15.

Place a supplied 3

⁄

” clamp

onto the front of the supplied rear

intermediate pipe.

16.

Install the supplied rear

intermediate pipe onto the catalytic

converter outlet. Lightly snug the

⁄

” clamp onto the front of the

intermediate pipe / catalytic converter

outlet.