Banks Power Ford Trucks: (Diesel ’03 - 07 6.0L Power Stroke) Power Systems- PowerPack & Stinger w EconoMind ('03-07) Compatible w_ Optional PowerPDA - Manual (Page 21)

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BANkS TECHNI-COOLER
INSTALLATION
36.
For 2003 vehicles only: Remove
the rubber air deflectors from the
face of the stock cAc. Install the
rubber air deflectors removed from
the stock cAc on the Banks cAc. Use
the supplied zip tie mounts to affix
the air deflectors to the Banks cAc.
Discard the supplied zip tie mounts
for vehicles that are not equipped
with the rubber air deflectors.
37.
Remove the rubber saddle
mounts and grommets used to mount
the stock cAc and install them on the
Banks cAc.
38.
Install the Banks cAc into the
factory lower saddle mounts.
39.
Reinstall the upper radiator
support. Leave the 8 bolts that retain
the support hand tight. This will allow
the position of the upper core support
to be aligned with the Banks cAc.
40.
Install the bolt at each of the
upper cAc mounts and torque to 19
ft-lbs.
41.
Torque the eight upper radiator
support bolts to 22 ft-lbs.
42.
Reinstall the radiator support
brackets and torque to 22 ft-lbs.
43.
Re-affix the two upper air
conditioning condenser mounts and
torque to 80 in-lbs.
44.
Re-attach the hood latch in the
outline that was previously marked.
Torque the hood latch bolts to 9 ft-lb.
45.
Re-attach the pushpins that
attach the driver and passenger side
air deflectors to the radiator support.
46.
Re-install the upper radiator air
deflector with pushpins.
HIGH-RAM INSTALLATION
47.
Apply the supplied thread locker
to the M6 threaded side of the High
Ram studs. The M6 thread length is
shorter than the 1 ⁄ 4 ”-20 threads on
the opposite ends of the studs.
48.
Using the two 1 ⁄ 4 ”-20 nuts
provided, tighten the High Ram studs
into the intake manifold by threading
both nuts onto the stud. Tighten the
nuts against each other using two
open-end wrenches, then tighten the
stud by turning the wrench on the top
nut. The stud should be torqued to 2
ft-lbs. Reverse the process to remove
the nut and repeat for each stud.
49.
2003 to 2004 vehicles only:
Remove 0.75” of the split loom near
the connector shown in Figure 19 to
provide additional clearance for the
High-Ram.
50.
Install the supplied o-rings on the
two driver side studs as shown in the
exploded view in Figure 20. Slide the
o-rings down to the base of the intake
manifold.
51.
For 2003 to 2004 vehicles,
install the factory replacement intake
manifold gasket in the groove on the
intake manifold. For 2005-06 vehicles,
install the factory replacement intake
manifold gasket on the High Ram.
52.
Slide the High-Ram over the
installed studs.
53.
Place the thread sealing washers
on the two driver side studs. Use a
twisting motion to thread the sealing
washers over the threaded portion of
the studs to avoid tearing the seals.
Install standard flat washers on the
passenger side studs and on top of
the thread sealing washers, as shown
in Figure 20.
Figure 19