Gale F250 User's Manual
Contents
1. LHOI 30490402 gsulebe 2284 7 L 7 m ee em 14 96547 v 1 0 Template 2 For Left Side of undercarriage fender r 15 96547 v 1 0 Banks Engineering 546 Duggan Avenue Azusa 91702 626 969 9600 Fax 626 334 1743 Product Information amp Sales 800 438 7693 Customer Support 888 839 5600 bankspower com2. 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 2 96547 v 1 0 Tools Required 1 2 and 38 drive ratchets with inch and metric sockets and 1 2 and 38 drive extension Inch and metric combination or open end wrenches Standard screwdriver Clean shop towels or rags Reciprocating saw Highly recommended tools and supplies Foot pound torque wrench Penetrating oil or light lubricant spray 96547 1 0 Figur
3. clamp onto the inlet of the pipe extension Install extension pipe onto the intermediate pipe and loosely snug the exhaust clamp 9 Install the rear hanger clamp onto the intermediate pipe outlet with the hanger pins facing the front of the vehicle Insert the two 2 hanger pins into the rear rubber hangers and adjust the hanger clamp to a position that best supports the intermediate pipe see Figure 3 6 96547 v 1 0 Figure 2 See Table 1 for cutting length gt Table 1 2008 Ford Power Stroke 6 41 Wheel Base Cut this length from the Intermediate Pipe See Figure 2 Crew Cab Short Bed 156 2 Crew Cab Long Bed 172 8 Figure 3 RUBBER INSULATOR RUBBER INSULATOR SHOULD BE POSITION D ALLOW SLIDING WHEN FACTOKY FIN EXHAUST PIPE EXPANDS 74 HANGER PIN Front of vehicle DIRECTION OF PIPE EXPANSION 96547 v 1 0 7 Figure 4 FACTORY LEAF 97 K re 7 16 HARDWARE INSULATOR BANKS HANGER BRACKET FACTORY FRAME v SLOT BANKS La RUBBER BANKS FORWARD DRIVER SIDE TAILPIPE 10 install the Y pipe over the intermediate pipe as shown in Figure 1 Install clamps onto each Y pipe outlet 11 Locate the two slots on the rear diverside frame rail and install the supplied Banks hanger bracket using the supplied hardware Be sure the hanger pin is align parallel to the frame rail and torque the hardware to 48ft Ib See F
4. e 1 General Assembly Diagram Item Description P N Qty 1 Intermediate Pipe 1 3 Y Pipe 53993 1 Tail Pipe Left 53994 1 5 Tail Pipe Right 53995 1 Exhaust Clamp 3 5 52468 3 7 Exhaust Clamp 4 52470 1 8 Hanger Clamp Intermediate 53986 1 9 Hanger Clamp Rear 53989 1 10 Frame Hanger Bracket 53566 1 11 Nylock Nuts 7 6 20 91617 2 12 Washers 7 16 91603 4 13 Hex Bolt 7 16 20 x 1 91627 2 14 Rubber Insulator 53732 1 15 Black 5 Cable Tie 62001 3 16 Banks Urocals 96009 2 For Crew Cab Long Bed only Facto Diese Particulate Filter 96547 v 1 0 Monster Exhaust System Installation 1 As a precaution disconnect the ground of the battery if there is more than one battery disconnect both 2 Raise the vehicle and support it with 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 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 re
5. egin to tighten the clamps starting with the ones closest to the turbo and working your way back Evenly torque the exhaust clamps to 35 ft Ibs Make sure that each slip is fully inserted 1 4 inch 19 Remove the protective covering from the tailpipe tip Caution The protective covering may ignite and burn if not removed prior to running the engine 20 Re route any vent hose or brake lines away from the tailpipe using the supplied Cable ties 21 Your system includes two Banks Power logos designed to complement the Ford badging on your truck Use the provided measurements see Figure 8 to position the logos for a clean factory look 22 Re connect battery terminals Start the engine and listen for exhaust leaks Tighten the exhaust clamps as necessary Whenever possible tack weld slip connections to prevent disengagement is recommended 23 The Banks Monster Exhaust installation is now complete 10 96547 v 1 0 Figure 8 SUPER DUTY ve POWER STROKE TYPICAL LEFT FENDER _ SUPER OUTY TYPICAL RIGHT FENDER 96547 v 1 0 11 2008 Ford 250 350 6 41 Power Stroke Banks Split Dual Monster Exhaust Quad Tip 12 96547 v 1 0 Page Left Intentionally Blank 96547 v 1 0 13 Template 1 For Right Side of undercarriage fender 1 T d 2
6. igure 4 12 Install the supplied rubber insulator onto the Banks hanger bracket 13 Install the driver side tailpipe onto the left Y pipe outlet Install the driver side tailpipe hanger into the vehicle rubber insulator Position the rubber insulator as shown in Figure 5 14 install the passenger side tailpipe onto the right Y pipe outlet Install the passenger side tailpipe hanger into the vehicle rubber insulator Position the rubber insulator as shown in Figure 3 15 Loosen and move the spare tire to the rear of the vehicle and center between the dual tailpipes Securely tighten the spare tire so that it is retained in place see Figure 6 8 96547 v 1 0 Figure 5 Figure 6 ADJUST SO THAT SPARE TIRE TO HEAT SHIELD CLEARANCE 19 WITHIN 1 2 BANKS DRIVER SIDE TAILPIPE ZIP TIE ON VENT HOSE amp BRAKE LINE HANGER ANGLE SHOULD ALLOW PIPE TO EXPAND TOWARD REAR OF VEHICLE FORWARD E MOVE SPARE TIRE TOWARDS REAR OF VEHICLE BANKS PASSENGER SIDE TAILPIPE 96547 v 1 0 9 m Figure 7 Placement of template on Passenger side rear undercarriage lining 16 Adjust the Tailpipe Tips under the rear fender such that the tip position is aesthetically pleasing 17 Use Template 1 and or 2 on page 14 amp 15 to trim the rear undercarriage fender lining as shown in Figure 7 for the LEFT and RIGHT side of the vehicle 18 with everything positioned properly b
7. sult in severe injury 3 starting at the rear of the vehicle remove the tailpipe near the intermediate pipe clamps by cutting through the connection or by removing the clamps and heating the joints with an oxy acetylene torch to allow crimped pipes to separate Remove the tailpipe from the vehicle 4 Remove the clamps on the Diesel Particulate Filter to intermediate pipe TAKE CAUTION TO NOT CUT OR DAMAGE DIESEL PARTICULATE FILTER TUBING DURING THE REMOVAL PROCESS Separate the intermediate pipe to Diesel Particulate Filter connection Note the use of an oxy acetylene torch may be necessary Remove the intermediate pipe hanger pins from the rubber hangers with a pry bar Spray lubricant will ease hanger removal and remove the intermediate pipe assembly from the vehicle 5 Locate the supplied intermediate pipe and cut the intermediate pipe based on the following configurations See Table 1 Cut the NON swedged end of the intermediate pipe See Figure 2 6 Install a 31 2 exhaust clamp onto the front of the Banks intermediate pipe Install the intermediate pipe onto the Diesel Particulate Filter outlet Loosely snug the 312 clamp 7 For Crew Cab Long Bed Models Only all other models skip to step 9 Slide the supplied hanger clamp onto the intermediate pipe Insert the hanger pin into the factory rubber hanger See Figure 1 8 Locate the supplied intermediate pipe extension Install supplied 4 exhaust
8. with Installation Instructions 2008 Ford Power Stroke 6 41 Turbo Diesel F250 F350 Trucks THIS MANUAL IS FOR USE WITH SYSTEM 49786 amp 49787 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 bankspower com 2008 Gale Banks Engineering 3 28 08 PN 96547 v 1 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 4 Disconnect the negative ground cable from the battery or batteries if there are two before beginning work 5 Route and tie wires and hoses minimum of 6 away from exhaust heat moving parts and sharp edges Clearance of 8 or more is recommended where possible
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