Banks Power Ford Trucks: (Gas ’87 - 97 7.5L EFI) PowerPack, Stinger & TorqueTube system '87-97 For Use w_ 460 EFI Engine - Manual (Page 4)

4 P.N. 96352
exHausT sYsTeM insTallaTion PRoceduRe
For Stinger installation, proceed to step 3.
1.
Unbolt air filter cover. Remove air filter cover and
entire air inlet hose assembly as a unit by
loosening hose clamps at the throttle body on the
engine. Cover throttle opening to prevent foreign
objects from entering.
2.
Remove sparkplug wires from sparkplugs. label
wires for reinstallation if not familiar with firing
order. lay sparkplug wires away from exhaust
manifolds. Now remove sparkplugs from engine.
For torquetube only installation, proceed to step 5.
3.
Remove muffler and tailpipes from over rear
axle. If this assembly will not be reused, cutting
off the tailpipes will allow the muffler/tailpipe assembly
to be removed more quickly. If this assembly is to be
saved intact, the vehicle must be raised high enough so
the muffler/tailpipe assembly can be lifted over the rear
axle.
Heat from a torch will most likely be required to
separate slip joints. To remove the exhaust system from
the rubber hangers, squirt some WD40, silicone spray
or similar lubricant onto the lower end of the rubber
hangers, where the hanger rod protrudes through the
rubber, then use a pry bar to pop the rubber hangers off
the rod.
4.
Remove the intermediate pipe from between the
muffler and catalytic converter. This will be a
short stub adapter on short wheelbase models, or a
pipe, or pipe with hanger on longer wheelbase models.
Heat the catalytic converter outlet slip joint as required
to remove the pipe.
For Stinger installation, proceed to step 19.
5.
Disconnect the oxygen sensor plug where
oxygen sensor wires join the wire loom (not at
the oxygen sensor). Carefully unscrew the oxygen
sensor from the exhaust Y-pipe. On 1996 and later
California trucks, disconnect and remove all three
oxygen sensors. Be sure to note and label the sensors
and wire connectors to ensure that upon reinstallation
each is returned to its original location.
6.
Separate the catalytic converter from the Y-pipe
assembly and the air injection tubing. Use heat
at slip joints as required. Remove Y-pipe assembly by
unbolting flanges at exhaust manifolds.
7.
On vehicle models with air injection into the
exhaust manifolds, unbolt the air injection tube
from the rear of the right exhaust manifold. Penetrating
oil may be necessary for bolt removal.
8.
Remove dipstick and dipstick tube from left
exhaust manifold and oil pan. Disconnect air
injection tube (if equipped) and EGR tube from fittings on
rear and bottom of left exhaust manifold. Use penetrating
oil as required.
NOTE: Unscrew tubing nut from fittings on exhaust
manifold, do not attempt to remove the adapter fittings
from the manifold. In extreme cases, heat from a torch
may be required to loosen the tube nuts. Heat the nut
to a dull red color, let it cool, then spray the nut with
penetrating oil and attempt to loosen the tube nut. DO
NOT kink or deform the tubes.
9.
Unbolt and remove exhaust manifolds from
engine, loosen any brackets attached to exhaust
manifold bolts as required (other side of brackets may
be left attached to engine during manifold removal).
Remove and retain sparkplug wire heat shields, if
equipped. Mark right and left heat shield for
reinstallation.
NOTE: Banks TorqueTubes are designed to allow for
the reinstallation of the factory spark plug heatshields.
However, due to the nature of tubular manifolds,
heat retention is not a problem and the spark plug
heatshields may be eliminated. Should you decide
to reinstall the heatshields, instructions to do so are
provided.
iMPoRtant
On Super-Duty and 1-ton 4WD trucks, a Banks Sway
Bar link Bracket (Part #48899) must be installed at
this time (before installing Banks TorqueTubes) for
clearance. Please see information on page 3 for bracket
installation.
10.
Inspect the exhaust manifold flange surfaces on
the cylinder heads. Remove any foreign material
from these surfaces that might prevent proper manifold
sealing. If cylinder heads have been heavily eroded from
leaking factory manifolds, exhaust manifold gaskets will
be required, or the heads must be removed and the
exhaust flange area resurfaced as necessary. Otherwise,
no gaskets are used between the Banks TorqueTube
manifolds and the cylinder head, as the Banks manifolds
have machined flanges like the original factory iron
manifolds.
11.
Install right-hand Banks TorqueTube ® manifold
from under the vehicle. See caution note on
jacking and raising vehicle in Preparation and
Precautions section. Install all bolts finger-tight, then
tighten bolts from the center out. Use a dab of anti-
seize lubricant (provided)on the bolt threads where they
enter the head. See Figure 1 for bolt locations.
Reconnect air injection tube (if used) two-bolt flange at
rear of TorqueTube head flange. (Only manifolds for air
injected engines will have this flange.)
Use new gasket, provided, two 5 ⁄
16
-24 x 5 ⁄
8
hex bolts,
and four 5 ⁄
16
” circle-lock washers. Washers are used in
pairs on each bolt, the ramps on the surface of each