Owner’sManual with Installation Instructions Banks High-Ram® Intake 2003-2007 Dodge 5.9L Cummins (24-valve) ISB Pickup Trucks THIS MANUAL IS FOR USE WITH SYSTEM 42726 & 42765 Gale Banks Engineering 546 Duggan Avenue • Azusa, ca 91702 (626) 969-9600 • Fax (626) 334-1743 Product Information & Sales: (888) 635-4565 bankspower.com ©2010 Gale Banks Engineering 9/24/10 PN 96768 v.8.
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General Installation Practices 4. The installation should be Dear Customer, If you have any questions concerning the installation of your Banks High Ram Intake, 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. For ease of installation of your performed at time when the vehicle has been allowed to completely cool.
STOCK RAM REMOVAL 1. Loosen the clamp that holds the 4. Unbolt and remove the 4 bolts Caution: Cover the intercooler up-pipe opening with a clean rag to prevent foreign objects from entering the intake tract. 5. Remove the stud bolt from the rubber hose at the inlet of the stock intake and slide the hose free of the intake inlet. Save the clamp for re-use. 2. Remove the bolt that holds the dipstick on the intake. Save the bolt for reuse.
7. Being careful not to scratch or gouge the mating surfaces of the parts, completely remove the stock gaskets from both sides of the heater element block and intake manifold, using a gasket scraper as needed. Clean and dry all sealing surfaces thoroughly. 8. Reinstall the electric heater element block onto the intake manifold, placing one of the supplied gaskets between it and the intake manifold. Reattach the three electrical connections to the heater element.
Figure 3 Figure 4 96768 v.8.
11. If your vehicle is NOT equipped with a factory ground strap on the intake heater, install the supplied ground strap from the intake heater to the engine. Put a 6-mm washer onto the bottom intake heater stud, leaving the factory heater nut installed. Next, install the smaller diameter ground strap terminal over the stud and retain with a 6-mm washer and nut. Route the other end of the ground strap to the threaded section on the engine and retain with a SAE washer and M8-1.25x 16 bolt. See Figure 2. 12.
14. Slide the second provided intake gasket over the four studs and set the High-Ram in place on the studs. Twist a Stat-o-seal washer over the inner two studs, then over each stud install a flat 5⁄ 16” AN washer. Install a 5⁄ 16 -24 nylock nut on each stud and tighten all four evenly between 140 to 150 lb-in. See Figure 5. Caution: Use only handtools when tightening the High-Ram. Tighten snugly but do not overtighten.
17. Remove all rags from the Note: For 2004-2007 model vehicles, locate the supplied corrugated loom in your kit and install over the main connector wires to protect it from rubbing against the dipstick. See Figure 7. 18. Rotate dipstick bracket and align 19. Reconnect the batteries. The intercooler up-pipe opening and reconnect the rubber hose from the intercooler up-pipe to the High-Ram and tighten the clamp to 100 lb-in (11 N-m). the dipstick bracket hole to the hole on the High-Ram.
NOTES 96768 v.8.
Gale Banks Engineering 546 Duggan Avenue • Azusa, ca 91702 (626) 969-9600 • Fax (626) 334-1743 Product Information & Sales: (888) 635-4565 bankspower.
