Gale Banks Engineering - Diesel Performance Specialists F250 User's Manual
Contents
1. CENTER TO CENTER 96782 V 2 0 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 TRIM HERE USING TEMPLATE 1 pe TURBO Dies 96782 V 2 0 5 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 6 Stud High Ram Air Intake M6 1 0 x Va 20 x 4 365 91534 3 7 Stud High Ram Air Intake M6 1 0 x 14 20 x 6 725 91535 1 8 Nut Nylock YVa 20 91110 4 9 Washer SAE Flat Zinc Va 91102 4 10 Washer Thread Sealing YVa 20 91106 2 11 O Ring High Ram 93606 2 12 Hose Clamp 3 5 Spring Loaded 92897 2 13 Hose Clamp 3 0 Spring Loaded 92860 2 14 Spacer Battery Box 91890 1 15 Hex Bolt Washer Head Black 8mm 1 25 x 30mm 91810 2 6 96782 v 2 0 Figure 7 CUT THE SPLIT LOOM WIRE COVER BACK TO THIS POINT TO PROVIDE CLEARANCE FOR THE HIGH RAM High Ram Installation 20 Apply the supplied thread locker to the M6 threaded side of the High Ram studs The M6 thread length is shorter than the Ya 20 threads on the opposite ends of the studs 21 Using the two Ya 20 nuts provided tighten the High Ram studs i2. 9 Remove the wire harness plastic retaining clip on the back of the plastic battery box 10 Remove the plastic battery box Ax 13mm socket For 2005 06 4 wheel drive equipped vehicles only A small bracket used to mount an electronic module will also be removed with the plastic battery tray 96782 V 2 0 3 4 Figure 3 11 Locate the driver side boost o 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 DRILL A 3 8 INCH getting into this area DIAMETER HOLE AT THIS Modifications to make room for LOCATION ONCE THE i BATTERY BRACKET HAS the Banks Techni Cooler System BEEN REMOVED FROM 15 For 2005 06 4 wheel drive E E f THE VEHICLE equipped vehicles only Remove the two retaining clips that attach the wire harness to the metal battery tray 16 Remove the driver s side metal battery tray 3x 13mm socket 17 Drill a Y3 inch hole as shown in Figure 3 18 Reinstall the battery tray as shown in Figure 4 with the supplied 12 spacer and longer supplied 8mm bolts Torque the bolts to 12 ft lbs el 1 2
3. DULE Figure 2 SS P gt DEPRESS THE TAB AT THE FRONT AND REAR OF THE BATTERY COVER TO REMOVE 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 vehicles only Remove the electronics module near the driver side battery shown in Figure 1 The retaining tab for the module can be pried back with a flat blade screwdriver as shown in the figure After the tab is depressed the module can easily be pulled away from it s mounting bracket 6 Remove driver s side plastic battery cover There are tabs at the front and back of the cover that need to be depressed to remove the cover as shown in Figure 2 Note Be careful not to break the plastic box as it will be re installed later 7 Remove the driver s side battery hold down clamp 8mm socket 8 Remove the driver s side battery WARNING When lifting a battery excessive pressure on the end walis could cause acid to spew through the vent caps resulting in personal injury Lift with a battery carrier or with hands on opposite corners Failure to follow these instructions may result in personal injury
4. banks with Installation Instructions OwnersMar 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 amp 42751 Gale Banks Engineering 546 Duggan Avenue e Azusa CA 91702 626 969 9600 e Fax 626 334 1743 Product Information amp Sales 888 635 4565 Customer Support 888 839 5600 Installation Support 888 839 2700 bankspower com 9 4 2006 Gale Banks Engineering 10 30 06 PN 96782 v 2 0 2 Dear Customer If you have any questions concerning the installation of your Banks Techni Cooler 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 Tools Required e Drive ratchet e Ratchet extension e Inch and metric deep sockets e Pliers e Phillips and flat blade screwdrivers e Inch and metric open end wrenches Recommended tools e Foot pound torque wrench e Inch pound torque wrench 96782 V 2 0 General Installation Practices 1 Before starting work familiarize yourself with the installation procedure by reading all of the instructions 2 Throughout this manual the left side of the vehicle refers to the driver s side and the right side to the passenger s side 3 Disconnect the negative ground cable from
5. he High Ram with 4x Ya 20 Nylon locking nuts Torque to 9 ft lbs NOTE Before slipping the boost tube and the corresponding hose into position ensure that all connection ends are clean and free of any oil residue and contaminates Clean all connection points with a non oil based solvent such as Acetone Mineral Spirits Denatured Alcohol or Lacquer Thinner Read and follow the manufactures operation instruction for non oil based solvent cleaner 28 Locate the Banks boost tube connection hose hump hose and supplied hose clamps Install hoses hose clamps and Banks boost tube as shown in Figure 6 Note the connection hose should be slid firmly against the hose stops provided on the High Ram Allow a minimum 1 8 air gap between CAC High Ram and boost tubes Figure 9 weet i f ee are POSITION THE HOSE CLAMPS AS SHOWN TO AVOID CONTACT WITH THE HOOD On 2003 to 2004 vehicles The brake line on the driver side may need to be slightly bent to provide additional clearance for the boost tube On 2005 06 vehicles One of the power steering fluid lines may need to be bent to provide clearance for the driver side boost tube 29 The hose clamps on the High Ram must be positioned as shown in Figure 9 to avoid contact with the hood 30 Tighten the hose clamps to 75 inch Ibs not ft Ibs 31 Re install the plastic driver side battery box Torque the attachment bolts to 12 ft lbs On 2005 06 4
6. nto 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 ft lbs Reverse the process to remove the nut and repeat for each stud 22 2003 to 2004 vehicles only Remove 0 75 of the split loom near the connector shown in Figure 7 to provide additional clearance for the High Ram 23 Install the supplied o rings on the two driver side studs as shown in the exploded view in Figure 8 Slide Figure 8 NYLOCK NUT STANDARD WASHER THREAD SEALING WASHER BANKS HIGH RAM O RING STUD 96782 V 2 0 7 8 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 tearing the seals Install standard flat washers on the passenger side studs and on top of the thread sealing washers as shown in Figure 8 27 secure t
7. the battery or batteries if there are two before beginning work 4 Route and tie wires and hoses a minimum of 6 away from exhaust heat moving parts and sharp edges Clearance of 8 or more is recommended where possible 5 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 6 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 Figure 1 Electronic module near the driver side battery on 2005 06 4 wheel drive equipped vehicles PRY THE RETAINING CLIP BACK AS SHOWN WITH A FLAT BLADED SCREWDRIVER THEN REMOVE THE MO
8. wheel drive vehicles only Reinstall the electronic module mounting bracket that was removed with the plastic battery tray 32 Re install the driver s side battery battery hold down clamp and plastic battery cover Torque the hold down clamp retaining bolt to 89 in lbs WARNING When lifting a battery excessive pressure on the end walls could cause acid to spew through the vent caps resulting in personal injury Lift with a battery carrier or with hands on opposite corners Failure to follow these instructions may result in personal injury 33 For 2005 06 4 wheel drive equipped vehicles only Re install the electronic module near the driver side battery The module is shown in Figure 1 34 Re install the air filter assembly box and air box front cover 35 Re install the driver and passenger and battery cables 96782 V 2 0 Template 1 fan shroud step 19 9 96782 v 2 0 Notes 10 96782 v 2 0 Notes 96782 v 2 0 11 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 Customer Support 888 839 5600 Installation Support 888 839 2700 bankspower com
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