with Installation Instructions Owner’sManual Banks Monster Exhaust System ® 2003-2006 Ford Power Stroke 6.0L Turbo-Diesel F250/F350 Trucks & 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 & 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.
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.
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.
Figure 1 General Assembly Diagram 1 Turbine Outlet Pipe (T.O.P.
* Crew-Cab Long-Bed models contain two (2) 4" exhaust clamps ** Crew-Cab Short-Bed only *** Long-Bed only 10 16 19 15 14 8 18 17 9 13 4 11 20 5 6 7 96440 v.10.
the Banks exhaust system. Be careful not to trim an excessive amount of tubing. Be sure to wear proper safety equipment. 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). 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.
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. 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. 9. For crew-cab long-bed, extended-cab it is necessary to replace the factoryinstalled frame-mounted hanger pin that is located behind the rear transmission crossmember.
C) Reinstall the rubber hanger onto the mounted hanger pin assembly. 11. Install the single pin front hanger clamp onto 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.
fully inserted (+/- 1⁄ 4 inch) and that all mount hangers are in 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).
96440 v.10.0 2003 T.O.P w/Resonator Front Intermediate Pipe Exhaust Clamp, 4" Exhaust Clamp, 3.5" Owners Manual 53525 53526 52470 52468 96440 2004 T.O.P w/ Out Resonator Front Intermediate Pipe Exhaust Clamp, 4" Exhaust Clamp, 3.5" Owners Manual 53537 53526 52470 52468 96440 T.O.P. System (Build Date 10/03 & Later) Description (Build Date 9/03 & Earlier) P/N T.O.P. System 1 1 1 1 1 48781 1 1 1 1 1 48761 Std.
96440 v.10.0 11 Tailpipe Tailpipe (Excursion) Tailpipe Tip Hanger, Clamp, Front Muffler Hanger, Clamp, Rear Muffler Hanger Clamp, Front, Muffler (Excursion) Hanger Clamp, Rear, Muffler (Excursion) Exhaust Clamp, 4" Exhaust Clamp, 3.5" Rear Interm. Pipe (Kit 48750) Rear Interm. Pipe (Kit 48751) Rear Interm. Pipe (Kit 48752) Rear Interm. Pipe (Kit 48753) Rear Interm. Pipe (Kit 48754) Rear Interm. Pipe (Excursion) Frame Hanger, Muffler Nuts, Lock M8-1.
Gale Banks Engineering 546 Duggan Avenue • Azusa, CA 91702 (626) 969-9600 • Fax (626) 334 -1743 Product Information & Sales: (800) 438-7693 Customer Support: (888) 839-5600 Installation Support: (888) 839-2700 bankspower.
