Banks Power 2001-2004 (LB7) Chevy_GMC 6.6L Duramax Turbo-Diesel Pickups User Manual

Page 6

As a precaution, disconnect the

ground of the battery (if there is

more than one battery, disconnect

both).

Raise the vehicle and support it

with properly weight rated safety

stands, ramps or a commercial hoist.

Follow the manufacturer’s safety

precautions. Take care to balance

the vehicle to prevent it from slipping

or falling. When using ramps, be

sure the front wheels are centered

squarely on the topsides; place the

transmission in park; set the parking

brake and place blocks behind the

rear wheels.
CAuTIoN: Do NoT WoRK uNDeR

ANY VeHICLe SuPPoRTeD oNLY

BY A JACK. SeVeRe INJuRY MAY

ReSuLT.

Removal of the factory exhaust

can be simplified by cutting the

factory exhaust pipe behind the

muffler. This will allow the tailpipe to

be removed as a separate piece.

Remove the four (4) nuts from the

factory exhaust flange located at the

back side of the factory head pipe

(retain for re-use).

Remove the factory tailpipe

from the vehicle by disengaging the

exhaust system hanger pins from the

rubber hangers using a large screw-

driver or pry bar. Note: Lubricating

the rubber hangers with WD-40 or

similar lubricant will ease removal of

the hanger pins.

Remove the factory muffler from

the vehicle by disengaging the hanger

pins from the rubber hangers using a

large screwdriver or pry bar.
NOTE: If system 48682, 48683 or

48684 is being installed, perform

steps 7 thru 10 below. Otherwise

continue installation with step 11.

Spray penetrating oil such as

WD-40 on the T-bolt of the factory

v-band clamp to prevent galling.

Remove factory v-band clamp and

save for re-use.

Remove factory head pipe from

the vehicle by disengaging the

exhaust system hanger pins from

the rubber hangers using a large

screwdriver or pry bar.

Install Banks head pipe in vehicle

and insert the hanger pin in the

rubber exhaust hanger.

NOTE: Be sure to install the hanger

pin in the same location as the

previously removed factory head

pipe.

10.

Loosely install v-band clamp on

head pipe flange and only tighten

the T-bolt on the clamp to the point

that the pipe is snug but can still be

rotated in the clamp for adjustment/

alignment. NOTE: Do not completely

tighten the V-band clamp at this

point.
CAuTIoN: The following step

involves cutting a stainless steel

tube. Safety glasses should be

worn during any cutting operation

and care should be taken to avoid

injury due to sharp edges and

burrs.

11.

If the system is being installed

on an extended-cab long-bed or an

extended-cab short-bed vehicle, the

flange pipe that is supplied must be

trimmed to the appropriate length

prior to installation in the vehicle.

Once the cut has been performed,

debur the cut end with a file or

sandpaper. Figure 1 illustrates

the location of the required cut,

depending on vehicle configuration.

12.

Slide the supplied 4-inch band

clamp over the Banks flange pipe.

13.

Insert the flange pipe tube end

into the slip joint on the intermediate

pipe.
NOTE: Once the pipe has been

completely engaged in the slip joint,

it should be marked with a marker,

scribe or tape for reference when

tightening clamps later in the

installation. Each slip joint in the

system should be marked in this

fashion. When the exhaust system is

being adjusted to align the hangers,

the slip joints can be adjusted so that

the reference mark is no more than

⁄

” away from its original position.

14.

Install the intermediate pipe/flange

pipe to the 4-bolt flange using the

factory nuts (see note below). Install

the supplied gasket between the two

flanges. Torque nuts to 30 ft-lbs. NOTE:

If system 48682, 48683 or 48684 is

being installed, use supplied

⁄

nuts,

bolts and washers on 4-bolt flange and

torque to 40 ft-lbs.

15.

Slide one (1) of the supplied

4-inch exhaust clamps over the

Banks intermediate pipe. Note: On

extended-cab long-bed and crew-cab

long-bed vehicles, the clamp that is

used between the intermediate pipe

and muffler is a combination hanger/

clamp. When this hanger clamp is

installed the hanger pin should be

inserted into the factory rubber

hanger and the clamp should be

rotated until the hanger pin is parallel

with the frame mounted pin before

being torqued.

16.

Install the muffler onto the end

of the intermediate pipe. Be sure that

the inlet side of the muffler (see

markings on muffler body) is facing

toward the front of the vehicle. verify

that the muffler and intermediate

pipe are completely engaged.

17.

Slide one (1) of the supplied

4” exhaust clamps over the Banks

Dynaflow muffler outlet.

18.

Install the tailpipe into the outlet

of the muffler. Be sure that the two

pipes are completely engaged. Insert

the front and rear hanger pins into

the factory rubber hangers. Rotate

the tailpipe until the hanger pins are

parallel with the frame mounted pin.

NOTE: Minimum distance between

Section 1

exHAuST ReMoVAL

Figure 1

96773 v.7.0