Owner’sManual with Installation Instructions Banks Monster® Split-Dual Exhaust System 2003-2007 Ford Power Stroke 6.0L Turbo-Diesel F250/F350 Trucks THIS MANUAL IS FOR USE WITH Systems 47600-47614, 48761, 48781 Gale Banks Engineering 546 Duggan Avenue • Azusa, ca 91702 (626) 969-9600 • Fax (626) 334-1743 Product Information & Sales: (800) 438-7693 bankspower.com ©2010 Gale Banks Engineering 08/17/10 PN 96445 v.5.
Also Available from Banks Power 03-07 Ford 6.0L Banks iQ System (P/N 61151-61152) - 5” touchscreen interface that can control the Banks Diesel Tuner and/or SpeedBrake on the fly. - Interchangable gauge display, read and clear codes, monitor engine diagnostics, log data, time your vehicles runs and much more. Banks Ram-Air Intake System (P/N 42155) - Increases your airflow over stock. - Adds power, improves fuel economy, lowers EGTs and reduces smoke.
Boost and Pyro Gauges (P/N 64507) - Keep your engine safe by monitoring vital engine parameters OttoMind Programmer (P/N 66064) - Contains Banks tunes that boost your vehicles HP, Torque and MPG.
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.
Tools Required: Table of Contents • 1⁄ 2” and 3⁄ 8” drive ratchets with standard and metric sockets and 1⁄ 2” and 3⁄ 8” drive extension General Assembly . . . . . . . . . . . . . . 6 Exhaust System Installation . . . . .
General Assembly Figure 1 Ford Split-Dual Monster Exhaust Parts List Item # Part # Description 1 53525 / Turbine Outlet Pipe (Build date 9/03 & Earlier / 53537 Build date 10/03 & Later) 2 53526 Front Intermediate Pipe 3 53556- Rear Intermediate Pipe 53559** 4 53800 Monster Muffler 5 53574 Y-pipe 6 53575 Tailpipe Pass.
96445 v.5.
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.
6. The catalytic converter inlet will need to be trimmed to accommodate the Banks exhaust system. Be careful not to trim an excessive amount of tubing. Be sure to wear proper safety equipment. IMPORTANT: Diesel catalysts may become plugged with soot which can restrict exhaust flow, impeding performance. Inspect the converter by shining a powerful flashlight into the inlet. Observe the light through the other end of the converter.
11. Install the supplied rear Note: Inlet labeling stamped on the bottom of the muffler. Orient the Banks Monster emboss such that it is level with the frame. intermediate pipe onto the catalytic converter outlet. Be sure the notch and catalytic converter pin are properly aligned. Lightly snug the 31⁄ 2” clamp onto the front of the intermediate pipe / catalytic converter outlet. 15. For Short Bed models, install Note: Exhaust clamps should be placed at the beginning of the slot and evenly tightened.
Figure 4 FACTORY LEAF STOP BANKS HANGER BRACKET FACTORY FRAME SLOT BANKS 7/16” HARDWARE FORWARD the Driver side tailpipe over the axle and insert into the upper Y-pipe. Install the tailpipe hanger pin into the rubber grommet. 20. Route the Passenger side tailpipe over the axle and insert into the lower Y-pipe. Install the tailpipe hanger pin into the Banks rubber grommet. 21. Move the spare tire to the rear of the vehicle.
Figure 5 ADJUST SO THAT SPARE TIRE TO TAILPIPE CLEARANCE IS THE SAME MOVE SPARE TIRE TOWARDS REAR OF VEHICLE BANKS DRIVER SIDE TAILPIPE ZIP TIE ON VENT HOSE & BRAKE LINE 24. 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 recommended. The Banks Split-Dual Monster Exhaust installation is now complete. 12 96445 v.5.
Figure 6 Figure 7 96445 v.5.
96445 v.5.0 T.O.P. System (Build Date 9/03 & Earlier) P/N Description 53525 2003 T.O.P. w/Resonator 53526 Front Intermediate Pipe 52470 Exhaust Clamp 4” 52468 Exhaust Clamp 3.5” 96440 Owners Manual P/N T.O.P. System (Build Date 10/03 & Later) 53537 2004-2007 T.O.P. w/Out Resonator 53526 Fromt Intermediate Pipe 52470 Exhaust Clamp 4” 52468 Exhaust Clamp 3.5” 96440 Owners Manual Ext. Cab SB 141” WB 48761 1 1 1 1 1 48781 1 1 1 1 1 Std.
96445 v.5.0 15 P/N 53800 53574 53453 53455 53575 53576 53556 53557 53558 53559 53566 53732 91617 91603 91627 62001 52468 52476 96440 96503 Year Kit# Monster Muffler Y-pipe 03-07 Hanger, Clamp, Front Muffler Hanger, Clamp, Rear Muffler Tailpipe Pass. Side, 03-07 Tailpipe Drvr. Side, 03-07 Rear interm. Pipe, ECSB Rear interm. Pipe, CCSB Rear interm. Pipe, ECLB Rear interm.
Gale Banks Engineering 546 Duggan Avenue • Azusa, ca 91702 (626) 969-9600 • Fax (626) 334-1743 Product Information & Sales: (800) 438-7693 bankspower.
