Gale FORD 460 User's Manual
Contents
1. 1402 e 91402 P N 96346 V 2 0 GALE BANKS ENGINEERING 546 DUGGAN AVENUE e AZUSA CA 91702 626 969 9600 e FAX 626 334 1743 Product Information amp Sales 800 438 7693 www bankspower com2. ISCARD Affix the Do Not Discard sticker to the filter case included with every Banks replacement element Make sure you put the sticker in a highly visible place to alert your mechanic not to discard T PERFORMANCE HINTS m Service every 50 100 000 miles on street driven applications Service more often in offroad or heavy dust conditions If an air filter restriction gauge is installed then change the element when the air filter restriction reaches 18 H20 CAUTION Extremely fine dust from agriculture or offroad use will pull the oil from the element Frequent reoiling of the element s clean side might be required Completely service when practicable For extra protection use an air filter sealing grease on rubber ends of the element Service only with Banks air filter cleaner and Banks air filter oil PARTS LIST Banks Stinger System Ford 460 EFI Engine Std Ext Crew Cab Pickups 1987 93 1987 93 1993 96 1993 96 1996 1996 d p uo d wo ug 96 Excludes CA 96 Excludes CA CA Only CA Only 49207 49218 49250 49252 49253 49254 QTY DESCRIPTION PARTE PARTE PARTE PARTE PARTE PARTE 1 ADAPTER Cat Conv to Muffler 52601 52601 52604 52604 52604 52604 4 BOLT 6mm x 1 00 x 40MM 91760 91760 91760 91760 e e 1 CARD Product Registration 96392 96392 96392 96392 96392 96392 1 CLAMP Exhaust 2 52461 52461 e e e e T CLAMP Exhaust 3 user Rx i
3. OWNERS MANUAL WITH INSTALLATION INSTRUCTIONS DANI STINGER SYSTEM O FORD 460 EFI ENGINE 1987 96 STANDARD CAB PICKUPS THIS MANUAL IS FOR USE WITH SYSTEMS 49207 49250 and 49253 1987 96 EXTENDED CREW CAB PICKUPS THIS MANUAL IS FOR USE WITH SYSTEMS 49218 49252 and 49254 banio GALE BANKS ENGINEERING 546 DUGGAN AVENUE e AZUSA CA 91702 626 969 9600 e FAX 626 334 1743 Product Information amp Sales 800 438 7693 www bankspower com 2009 GALE BANKS ENGINEERING 02 06 09 P N 96346 V 2 0 This page intentionally left blank BANKS STINGER SYSTEM FORD 460 EFI TRUCK Dear Customer Your new Banks Stinger is a unique combination of air intake and exhaust components designed to make the most of your engine s power potential By removing intake and exhaust restrictions providing cooler intake air and tuning the exhaust to create a scavenging effect your engine can produce more power at a higher level of efficiency If your driving habits remain the same your fuel mileage should go up and you can run on the same octane fuel you are accustomed to using If you have any questions concerning the installation of the Banks PowerPack kit please call Gale Banks Engineering at 626 969 9600 between 8 00 am amp 5 00 pm PT and ask for the service department Thank you GENERAL INSTALLATION PRACTICES For ease of installation and trouble free E operation of your Banks Stinger System
4. d in the tube bending process burns off the pipes P N 96346 V 2 0 CLEANING AND OILING THE BANKS RAM AIR FILTER NOTIFICATION The Banks Ram Air Filter comes pre oiled and no oiling is necessary for initial installation Use Banks Ram Air Filter cleaning system part 490094 available from Gale Banks Engineering to service the Air Filter Follow the instructions included with the cleaning system to clean and re oil your Banks Ram Air Filter 1 PRE CLEANING El Tap the element to dislodge any large embedded dirt then gently brush with a soft bristle brush NOTE If complete cleaning is not practical at this time reoil the sr element and reinstall in your x vehicle I DI SPRAY ON CLEANING EE Spray Banks air filter cleaner liberally onto lt the entire element SA NN and let soak for 10 XA minutes AS PAN CLEANING Large air filter elements can be rolled or soaked in a shallow pan of Banks air filter cleaner Remove immediately and let soak for approximately 10 minutes 3 CLEANING HINTS EAE Use only Banks air filter cleaner NO gasoline cleaning NO steam cleaning NO caustic cleaning solutions NO strong detergents NO high pressure car wash NO parts cleaning solvents Any of these NOs can cause harm to the cotton filter media plus SHRINK and HARDEN the rubber end caps RINSE OFF Rinse off the element with low pressure water Tap water is okay Always flush from the c
5. lean side to dirty side This removes the dirt and does not drive it in to the filter P N 96346 V 2 0 E DRYING HINTS EE Always dry naturally After rinsing shake off all excess water and let the element dry naturally DO NOT USE COMPRESSED AIR DO NOT USE OPEN FLAME DO NOT USE HEAT DRYERS EXCESS HEAT WILL SHRINK THE COTTON FILTER MEDIA COMPRESSED AIR WILL BLOW HOLES IN THE Z N ELEMENT E nes AEROSO OILING After cleaning air filter always reoil before using Spray Banks Ram Air filter oil down into each pleat with one pass per pleat Wait 10 minutes and re oil any white spots still showing 7 OILING HINTS EN Never use a Banks Ram Air filter without oil the filter will not stop the dirt without the oil Use only Banks Ram Air filter oil Banks air filter oil is a compound of mineral and animal oil blended with special polymers to form a very efficient tack barrier Red dye is added to show just where you have applied the oil Eventually the red color Will fade but the oil will remain and filter the air NEVER USE Automatic Transmission Fluid NEVER USE Motor Oil NEVER USE Diesel Fuel NEVER USE WD40 LPS or other light weight oils REINSTALL Reinstall your Banks Ram Air filter element with proper care Make sure the element seats properly in the filter case Install the cover making Sure it s in the right position Tighten all the nuts bolts screws or clips to factory specifications DO NOT D
6. nd the extension pipe Most applications require that the extension pipe be cut to a specific length The following chart lists the extension pipe and adapter requirements for the various cab chassis applications 7 Crew Cab models use an additional hanger to support the center of the extension pipe A 3 clamp hanger is supplied with the 41 extension pipe l Cat Conv l E Cab Chassis Outlet Size Pipe Adapter X Modification Std Cab Long Bed 133 wheelbase 3 dia 3x 3 Adapter None Std Cab Long Bed 1 Ln 1 A n 133 wheelbase 2w da PX3 adapter None Super Cab Long Bed 155 wheelbase Extension Pipe Cut off 13 Super Cab Long Bed 1 0 Extension Pipe x 155 wheelbase 2 x 3 Adapter CU off 16 Crew Cab Long Bed l 168 wheelbase Extension Pipe None Crew Cab Long Bed 1 Extension Pipe 7 168 wheelbase 21x 3 Adapter Cut off 3 Crew Cab Short Bed m 152 wheelbase Extension Pipe Cut off 16 Super Cab Short Bed non g 139 wheelbase Extension Pipe Cut off 29 Install this hanger clamp into the factory rubber hanger to support the pipe Do not tighten at this time Install the muffler onto the catalytic converter or intermediate pipe Hang the muffler by the front and rear hanger clamps in the factory rubber hangers Leave clamps loose enough for adjustment 9 Install the Stinger tailpipe over the axle and into the muffler outlet Insert the pin on the tailpipe into the o
7. os dE SERE e 52465 52465 52465 52465 52465 1 CLAMP Exhaust 372 52467 52467 52467 52467 52467 52467 1 CLAMP Hanger 3 52288 52288 52288 52288 52288 52288 1 CLAMP Hanger 3 52696 52696 52696 52696 52696 52696 1 CLAMP Hanger 3 W ROd o o o 52689 o 52689 1 CLAMP Hanger Rear o o e 52289 00 o 52289 00 1 COVER Banks Ram Air 42520 42520 42520 42520 e o 1 DECAL Carb Rep Part 96024 96024 96024 96024 96024 96024 1 FILTER ELEMENT Banks Ram Air 41508 41508 41508 41508 41508 41508 1 MUFFLER Dynaflow Stainless w heat shield 52405 52405 52405 52405 52405 52405 1 o NUT 3 16CrimpLock o 91416 e 91416 1 OWNERS MANUAL 96346 96346 96346 96346 96346 96346 1 PIPE Intermediate o 52289 e 52290 o 52290 1 PIPE Tailpipe Extension Chrome 4 x 12 52281 52281 52281 52281 52281 52281 1 PIPE Monster Tailpipe Stainless 3 52683 52683 52683 52683 52683 52683 3 PLAQUE Banks PowerPack 96008 96008 96008 96008 96008 96008 1 SERVICE KIT Air Filter 90094 90094 90094 90094 90094 90094 1 WARRANTY STATEMENT 96362 96362 96362 96362 96362 96362 1 WASHER SAE cuc ucc dn ee Reha A e e e 9
8. please read this entire 8 page owner s manual before starting any work If any pages are missing from this package please call GALE BANKS ENGINEERING immediately for a replacement Become thoroughly familiar with all components amp phases of the installation amp determine what additional tools or materials you may need to complete the installation Any time the vehicle is raised off its wheels it should be supported by jack stands or ramps of adequate capacity for the vehicle s weight NEVER PERFORM ANY WORK UNDER A VEHICLE SUPPORTED ONLY BY ITS SERVICE JACK OR A HYDRAULIC JACK 2 NOTIFICATION The Banks Ram Air Filter comes pre oiled and no oiling is necessary for initial installation Service the filter as specified in the Cleaning and Oiling the Banks Ram Air Filter Section of this manual P N 96346 V 2 0 FIGURE 1 ue 2 1 2 or 3 TI ge U CLAMP E CENTER HANGER USE WITH CREW CAB AL M POWERPACK REAR i MUFFLER HANGER MUFFLER TO CAT CONVERTER ADAPTER YA e 3 U CLAMP USED WITH INTERMEDIATE PIPE INTERMEDIATE PIPE SUPER amp CREW CAB a CUT FOR WHEELBASE AS REQUIRED TAILPIPE TIP AND 3 1 2 U CLAMP TAILPIPE P N 96346 V 2 0 4 INSTALLATION INSTRUCTIONS 1 Raise vehicle See safety precautions page 2 If dll possible support vehicle from chassis and allow rear axle to hang 2 Remove muffler and tailpipes from over rear axle Ml If this assembly is to be
9. riginal factory rubber hanger Check the alignment of the muffler and tailpipe 10 Make sure tailpipe has adequate clearance to all chassis and suspension components minimum to nilo rattles When alignment looks good tighten all clamps 11 Lower the vehicle Remove the plastic silencer a from the engine air inlet hoses between the air cleaner housing and the throttle body Using a hacksaw remove the tapered portions PA of the silencer by sawing as shown in Figure 2 Remove any plastic shavings after cuts are completed Reinstall the modified silencer in the inlet air hoses Replace the original paper element type air KM filter with the low restriction reusable K amp N filter provided Make sure the filter is seated in the housing See the filter service section of these instructions for filter maintenance and care FIGURE 2 CUT OFF TAPERED PORTION HERE 14 Install new Banks Ram Air filter cover using four ill mm x 40mm metric hex bolts Tighten bolts just enough for cover feet to contact housing base Do not overtighten as this can distort cover and base Reinstall hoses and tighten clamps NOTE All 1996 California Only systems P N 49253 8 49254 reinstall factory air filter cover 15 Test drive the vehicle Listen for any exhaust leaks a and rattles Correct leaks and rattles by tightening or repositioning exhaust piping as required NOTE The exhaust system may smoke somewhat at first as the grease use
10. saved intact the vehicle must be raised high enough so the muffler tailpipe can be lifted over the axle If the tailpipes are not to be saved cutting the pipes will allow the assembly to be removed more quickly To remove the exhaust piping from the hangers squirt some WD4A0O or similar lubricant onto the lower end of the rubber hangers where the hanger rod protrudes through d a Now use a pry bar to pop the rubber hangers off the rod Remove the intermediate pipe from between the SEE 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 vehicles Install the converter to muffler adapter onto the catalytic converter outlet Install a 3 x 3 adapter on converters with a 3 outlet or a 27 x 3 adapter on converters with a 27 outlet When the adapter is in place install a 27 or 3 exhaust U clamp to secure the adapter If the vehicle is a Standard Cab not Super Cab SHE or Crew Cab model install a catalytic converter outlet adapter on the catalytic converter Install a 3 x 3 adapter on converters with a 3 outlet or a 2 x 3 adapter on converters with a 2 outlet See Figure 1 If the vehicle is anything other than the Standard Cab 133 wheelbase model an extension pipe must be used between the catalytic converter and the muffler Vehicles with catalytic converters having a 2 converter outlet will require the 2 x 3 adapter a
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