CJ Banks Automobile Parts 48784-48788 User's Manual
Contents
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3. VAL PROCESS To assist in removal the T O P should be cut before the transmission if it is going to be replaced Remove the hanger pins from the rubber hangers with a pry bar Spray lubricant will ease hanger removal 4 Remove the two 2 nuts attaching the turbine outlet pipe T O P to the catalytic converter inlet Loosen and remove the band clamp that attaches the rear intermediate pipe to the catalytic converter outlet Remove the catalytic converter assembly from the vehicle Remove the band clamp that attaches the T O P to the turbocharger and remove the factory T O P from the vehicle Retain V band clamp for re assembly Note To assist in T O P removal remove the rear engine hoist hook by removing the two 2 Hex screws and remove the valve cover heatshield The dipstick tube may also be removed or slightly bent to allow for T O P removal installation Retain all hardware and parts for reassembly For Manual Transmissions only the transmission will need to be lowered to allow for removal and installation of the T O P Using a Transmission Jack support the rear of the transmission to allow working room for the T O P and remove the rear transmission mount and crossmember Remove the Front drive shaft support bracket from the cab Lower the transmission 4 6 and remove the factory T O P The transmission may need to be raised before the Banks T O P is installed Install the Banks T O P Raise the transmis
4. el spacers onto the factory exhaust hanger studs Install the hanger spacer assembly into the vehicle frame holes about 10 16 to the rear of the original muffler hanger location see Figure 3 Note spacers are to be installed between the hanger pin and the inside of the frame rail Torque factory nuts to 20 ft lbs 10 For crew cab short bed models it is necessary to replace the factory installed frame mounted hanger pin that is located behind the rear transmission crossmember A Using a pry bar completely remove the rubber hanger from the front muffler hanger pin Remove the two 2 factory nuts on the front muffler hanger pin from the frame rail and remove the hanger pin from the vehicle Retain the rubber hanger for re assembly B Install the supplied hanger pin to the vehicle frame about 10 16 to the rear of the original muffler hanger location see Figure 3 Install the supplied bolts and washers into the hanger plate and through the frame Install the supplied nuts and torque to 20 ft lbs Figure 3 VEHICLE FRAME SUPPLIED 8MM NUTS SUPPLIED HANGER PIN SUPPLIED C Sp 5 16 WASHERS o tO SUPPLIED Om 2 BOLTS ORIGINAL HANGER MOUNTING LOCATION FIGURE SHOWS THE BANKS SUPPLIED HANGER PLATE ASSEMBLY 96440 v 10 0 7 C Reinstall the rubber hanger onto the mounted hanger pin assembly 11 Install the single pin front hanger clamp onto
5. l the supplied 31 2 clamp onto the outlet of the front intermediate pipe Place the trimmed catalytic converter onto the previously installed front intermediate pipe Loosely snug the clamp onto the catalytic converter inlet 7 Place a supplied 31 2 clamp onto the front of the supplied rear intermediate pipe Note Review the Parts List Table on page 11 to verify the rear intermediate pipe P N 8 Install the supplied rear intermediate pipe onto the catalytic converter outlet Be sure the notch and catalytic converter pin are properly aligned Lightly snug the 37 2 clamp onto the front of the intermediate pipe catalytic converter outlet For crew cab long bed models install the supplied extension pipe onto Figure 2 CUT LINE 6 96440 v 10 0 the intermediate pipe and snug a supplied 4 clamp onto the connection Note Exhaust clamps should be placed at the beginning of the slot and evenly tightened 9 For crew cab long bed extended cab short bed and extended cab long bed models it is necessary to relocate the factory installed frame mounted hanger pin that is located behind the rear transmission crossmember A Remove the two 2 factory nuts that mount the front muffler hanger pin to the frame rail and remove the hanger pin from the vehicle Note Extended cab short bed models will NOT use the two 2 3 8 spacers B Re install the frame mounted hanger pin using the two 2 3 8 long ste
6. minimum of 6 away from exhaust heat moving parts and sharp edges Clearance of 8 or more is recommended where possible 6 When raising the vehicle support it on 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 When raising the front of the vehicle put the transmission in park automatic or reverse manual set the parking brake and block the rear wheels When raising the back of the vehicle be sure the vehicle is on level ground and the front wheels are blocked securely Caution Do not use floor jacks to support the vehicle while working under it Do not raise the vehicle onto concrete blocks masonry or any other item not intended specifically for this use 7 During installation keep the work area clean Do not allow anything to be dropped into intake exhaust or lubrication system components while performing the installation as foreign objects will cause immediate engine damage upon start up Tools Required 1 2 and 3 8 drive ratchets with inch and metric sockets and 7 2 and 3 8 drive extension e Inch and metric combination or open end wrenches e Standard screwdriver e Clean shop towels or rags Pry bar Reciprocating saw Highly recommended tools and supplies e Inch po
7. n the forward position see Figure 4 16 Remove the protective covering from the tailpipe tip Caution The protective covering may ignite and burn if not removed prior to running the engine 17 Your system includes two Banks Power logos designed to complement the Ford badging on your truck Use the provided measurements see Figure 5 to position the logos for a clean factory look 18 Re connect negative battery cable s Start the engine and listen for exhaust leaks Tighten the exhaust clamps as necessary Whenever possible tack welding slip connections to prevent disengagement is Figure 5 TYPICAL LEFT FENDER 2 p v Du TY TYFICAL KIGHT FENDEK Feso m 96440 v 10 0 9 o L8Z8v B B lt 19287 uolsin5x3 L L L L L SI UAO OYE96 L L L L L S E dwejo 15 8 89725 L L L L L wv dwej9 35 0 925 L L L L L did 9a elpawWJa U 1401 92585 L L L L L JOYEUOSAY INO Md O L 7002 LESES V828V 18 87 18 87 8 87 18 87 19381 8 0 01 1eq 0118 W JS S L L L L L 5 0 7796 L L L L L S E dwejo 15 89725 L L L L L y dwej9 ysneyxy OZYZS L L L L L eIp uug uI 140 9ZGE S L L L L L d O L 6002 SCSES 1928 1928 1928 1928 1928 5 N d aM ZZL aM 8SL aM 9SL aM LVL aM ZEL 8182 8192 3x4 as
8. nly 96440 v 10 0 5 the Banks exhaust system Be careful not to trim an excessive amount of tubing Be sure to vvear proper safety equipment IMPORTANT Diesel catalysts may become plugged vvith soot vvhich can restrict exhaust flovv impeding performance Inspect the converter by shining a powerful flashlight into the inlet Observe the light through the other end of the converter The full circle of the flashlight should be visible without any blockage in the gridwork of the catalyst If excessive soot is observed the catalyst may need to be cleaned TAKE PRECAUTIONS to avoid blowing soot toward the work area or where it could be inhaled ALWAYS use breathing protection Also inspect the catalyst for damage i e chips bent corners etc to the gridwork If your catalytic converter is damaged it may be covered under your vehicle s emissions warranty A With the catalytic converter removed from the vehicle and the headpipe removed from the converter measure approximately 4 from the weld and mark the location this location should be before any bend about 7 rear of the inlet flange Using a reciprocating saw or equivalent vertically cut and remove 7 from the converter outlet tubing see Figure 2 B Install the supplied Banks front intermediate pipe onto the previously installed Banks T O P Loosely install a supplied 4 exhaust clamp onto the forward end of the front intermediate pipe C Instal
9. sion and reinstall drive shaft bracket transmission crossmember and rear transmission mount Refer to vehicles owners manual for factory Torque Specifications 5 Loosely place the factory V band clamp on the Banks T O P Install the Banks T O P to the turbine housing Loosely snug the V band clamp assuring the T O P is aligned properly Note Reinstall the engine hoist hook and valve cover heat shield if previously removed 6 The catalytic converter inlet will need to be trimmed to accommodate 96440 v 10 0 3 Figure 1 General Assembiy Diagram ON O O CO N gt A s xs x x 4a ON WoO GQ N O Turbine Outlet Pipe T O P 1 Front Intermediate Pipe 1 Rear Intermediate Pipe Crew Cab Long bed Crew Cab Short Bed 1 Extension Pipe Crew Cab Long Bed 1 Rear Intermediate Pipe Extended Cab Long Bed 1 Rear Intermediate Pipe Extended Cab Short Bed and Excursion 1 Rear Intermediate Pipe Regular Cab Long Bed 1 Banks Monster Muffler 1 Monster Tailpipe 1 Polished 5 Exhaust Tip 1 Exhaust Clamp 4 1 Exhaust Clamp 372 2 Hanger Clamp Front Muffler Hanger Clamp Rear Muffler Hanger Pin Assembly 1 Bolt 8 1 25x30mm 2 Washer Flat 5 16 2 Nut Lock 8 1 25mm 2 Spacers 8mm 2 Banks Power decals 2 4 96440 v 10 0 Crew Cab Long Bed models contain two 2 4 exhaust clamps Crew Cab Short Bed only Long Bed o
10. the rear of the intermediate pipe with the hanger pin on the inside facing the muffler Insert the hanger pin into the vehicle s rubber grommet Install the inlet of the Banks Monster muffler to the intermediate pipe 12 For F series Trucks install the dual pin rear hanger clamp onto the outlet of the Monster muffler with the hanger pins on the inside facing the muffler For Excursions install the rear hanger clamp with the pins facing to the rear of the vehicle Insert the two hanger pins into the vehicle s rubber grommets 13 Route the tailpipe over the rear axle housing and into the muffler outlet Install the tailpipe hanger pin into the corresponding rubber hanger Loosely snug the 4 hanger clamp onto the muffler outlet 14 Install the 5 Monster tailpipe tip on the exhaust Keep the wrapping on until installation is complete The tip should be rotated so the clamp nut and drain hole are pointing down Align the end of the tip with the body line of the truck 15 With everything positioned properly begin to tighten the clamps starting with the ones closest to the front and working your way back Torque the exhaust clamps evenly to 35 ft lbs Make sure that each slip is Figure 4 HANGER ANGLE SHOULD ALLOW PIPE TO EXFAND TOWARD REAR OF VEHICLE DIRECTION OF PIPE EXPANSION REAR OF VEHICLE 8 96440 v 10 0 fully inserted 1 4 inch and that all mount hangers are i
11. und and foot pound torque wrenches Penetrating oil or light lubricant spray e Transmission jack manual transmission 2 96440 v 10 0 Monster Exhaust System Installation 1 Disconnect the negative ground cable from the battery if there is more than one battery disconnect both negative cables Secure the cable so it cannot accidentally come in contact with the post 2 Raise the vehicle and support it securely with properly weight rated safety stands ramps or a commercial hoist Take care to balance the vehicle to prevent it from slipping or falling When using ramps be sure the wheels are centered squarely on the topsides Place the transmission in park automatic or reverse manual set the parking brake and securely block the wheels that are on the ground CAUTION DO NOT WORK UNDER ANY VEHICLE SUPPORTED ONLY BY A JACK SEVERE INJURY MAY RESULT WARNING The following step may require the use of a torch and or saw Proper safety equipment should be used Failure to use proper safety equipment may result in severe injury 3 From under the vehicle remove the factory exhaust system from the catalytic converter back Starting at the rear of the vehicle remove each component by either cutting through the pipe near the clamps or by removing the clamps and heating the joints with an oxy acetylene torch to allow crimped pipes to separate DO NOT CUT OR DAMAGE CATALYTIC CONVERTER TUBING DURING THE REMO
12. with Installation Instructions Banks Monster Exhaust System 2003 2006 Ford Povver Stroke 6 0L Turbo Diesel F250 F350 Trucks amp Excursions THIS MANUAL IS FOR USE WITH SYSTEMS 48755 48761 48764 48768 48781 48784 48788 Gale Banks Engineering 546 Duggan Avenue Azusa CA 91702 626 969 9600 Fax 626 334 1743 Product Information amp Sales 800 438 7693 Customer Support 888 839 5600 Installation Support 888 839 2700 bankspower com 2006 Gale Banks Engineering 03 07 06 PN 96440 v 10 0 General Installation Practices Dear Customer If you have any questions concerning the installation of your Banks Power System please call our Technical Service Hotline at 888 839 2700 between 7 00 am and 5 00 pm PT If you have any questions relating to shipping or billing please contact our Customer Service Department at 888 839 5600 Thank you 1 Before starting work familiarize yourself with the installation procedure by reading all of the instructions 2 The exploded view Figure 1 pages 4 5 provides only general guidance Refer to each step and section diagram in this manual for proper instruction 3 Throughout this manual the left side of the vehicle refers to the driver s side and the right side to the passenger s side A Disconnect the negative ground cable from the battery or batteries if there are two before beginning work 5 Route and tie wires and hoses a
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