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with Installation Instructions
Owner’sManual
®
Banks High-Ram
Assembly
2003-2006 Ford Power Stroke 6.0L Turbo-Diesel
F250/F350/F450/F550 Trucks
THIS MANUAL IS FOR USE WITH SYSTEMS 42750 & 42751
Gale Banks Engineering
546 Duggan Avenue • Azusa, CA 91702
(626) 969-9600 • Fax (626) 334-1743
Product Information & Sales: (888) 635-4565
Customer Support: (888) 839-5600
Installation Support: (888) 839-2700
bankspower.com
©2006 Gale Banks Engineering 10/30/06 PN 96782 v.2.0
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precautions. Take care to balance the General Installation vehicle to prevent it from slipping or Dear Customer, Practices falling. When using ramps, be sure If you have any questions the front wheels are centered 1. Before starting work, familiarize concerning the installation of squarely on the topsides. When yourself with the installation your Banks Techni-Cooler, please raising the front of the vehicle, put procedure by reading all of the call our Technical Service Hotline the transmission i
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Figure 1. Electronic module near the driver side battery on 2005-06 4-wheel drive equipped vehicles Remove Stock Components 1. Remove the (+) and (-) battery cables from both the drivers and passenger side batteries. 2. Undo the two toggle clamps at the rear of the air box assembly. 3. Disengage the two tabs on the lower backside of the air box assembly from the slots on the rear cover. 4. Remove the air box assembly and air box front cover from the vehicle. 5. For 2005-06 4-wheel drive equipped
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Figure 3 11. Locate the driver side boost tube. Loosen the hose clamps and remove the boost tube, hose clamps and hose (if applicable) from engine compartment and set aside. These parts will not be reused. 12. Remove the four allen head bolts that attach the stock intake elbow. The intake elbow is the 90 degree transition from the driver side boost tube to the intake manifold. 13. Remove the stock intake elbow and gasket. 14. Cover the inlet to the intake manifold to prevent debris from getting
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Figure 5 19. Trim the fan shroud as shown in Figure 5 using Template 1 on page 9, to clear the Banks High Ram. Note: 2005-06 vehicles require a different trim to fan shroud, use appropriate template. See Template 1. 96782 v.2.0 5
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Figure 6 General Assembly Banks Techni-Cooler Item Description P/N Qty 1 High-Ram Intake Manifold 2003-04 42745 1 2005-06 42746 1 2 Boost tube, left 41326 1 3 Hose, 3.5”x 3.25”, Black 94215 1 4 Hump Hose, 3” x 3”, Blue 94510 1 5 Gasket, High-Ram Intake 93038 1 1 6 Stud, High-Ram Air Intake M6-1.0 x ⁄4-20 x 4.365 91534 3 1 7 Stud, High-Ram Air Intake M6-1.0 x ⁄4-20 x 6.725 91535 1 1 8 Nut, Nylock ⁄4”-20 91110 4 1 9 Washer, SAE Flat, Zinc ⁄4” 91102 4 1 10 Washer, Thread Sealing ⁄4”-20 91106 2
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Figure 7 High-Ram Installation 20. Apply the supplied thread locker to the M6 threaded side of the High Ram studs. The M6 thread length is 1 shorter than the ⁄4"-20 threads on the opposite ends of the studs. 1 21. Using the two ⁄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 2-3 f
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Figure 9 the o-rings down to the base of the intake manifold. 24. 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. 25. Slide the High-Ram over the installed studs. 26. 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 tear
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Template 1 (fan shroud, step 19) 96782 v.2.0 9 2005-06 AREA TO TRIM 2003-04 2005-06 SHROUD AREA TO TRIM 03-04 SHROUD SUPPORT PIN SUPPORT PIN HIGH RAM ALIGN WITH SHROUD FAN SHROUD TEMPLATE SHROUD EDGE SUPPORT PIN
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Notes 10 96782 v.2.0
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Notes 96782 v.2.0 11
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Gale Banks Engineering 546 Duggan Avenue • Azusa, CA 91702 (626) 969-9600 • Fax (626) 334-1743 Product Information & Sales: (800) 438-7693 Customer Support: (888) 839-5600 Installation Support: (888) 839-2700 bankspower.com
