with Installation Instructions Owner’sManual 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 & 42751 Gale Banks Engineering 546 Duggan Avenue • Azusa, CA 91702 (626) 969-9600 • Fax (626) 334 -1743 Product Information & Sales: (888) 635-4565 Customer Support: (888) 839-5600 Installation Support: (888) 839-2700 bankspower.com ©2006 Gale Banks Engineering 10/30/06 PN 96782 v.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.
Figure 1. Electronic module near the driver side battery on 2005-06 4-wheel drive equipped vehicles 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.
11. Locate the driver side boost Figure 3 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.
Figure 5 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. 96782 v.2.
Figure 6 General Assembly Banks Techni-Cooler Item P/N Qty 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 1⁄ 4-20 x 4.365 91534 3 7 Stud, High-Ram Air Intake M6-1.0 x 1⁄ 4-20 x 6.
Figure 7 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 1⁄ 4"-20 threads on the opposite ends of the studs. 21. Using the two 1⁄ 4"-20 nuts provided, tighten the High Ram studs into 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.
Figure 9 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.
N SHR SUP OUD POR T PI ARE 2003 A TO -04 TRIM ARE 2005 A TO -06 TRIM FAN H SHR IGH RA OUD M TEM PLA TE 04 SUP SHROU POR D T PI N 03- 200 SUP 5-06 S POR H T PI ROUD N ALI G SHR N WIT OUD H EDG E Template 1 (fan shroud, step 19) 96782 v.2.
Notes 10 96782 v.2.
Notes 96782 v.2.
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.
