CJ Banks 48755, 48784, 48764, 48781, 48761 User Manual

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
[phone] • Fax [phone]

Product Information & Sales: [phone]
Customer Support:
Installation Support: [phone]

bankspower.com

©2006 Gale Banks Engineering

[phone]

03/07/06 PN 96440 v.10.0

General Installation Practices

the topsides. When raising the front

Dear Customer,

If you have any questions
concerning the installation of
your Banks Power System,
please call our Technical Service
Hotline at [phone]
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. The exploded view (Figure 1, pages

4-5) provides only general guidance.
Refer to each step and section diagram
in this manual for proper instruction.

3. Throughout this manual, the left

side of the vehicle refers to the
driver’s side, and the right side to
the passenger’s side.

4. Disconnect the negative (ground)

cable from the battery (or batteries, if
there are two) before beginning work.

5. 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.

6. 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

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.

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.

Caution! Do not use

7. 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.

Tools Required:

•1⁄2" and 3⁄8" drive ratchets with inch
and metric sockets and
drive extension

• Inch and metric combination or
open-end wrenches

• Standard screwdriver

• Clean shop towels or rags

• Pry-bar

• Reciprocating saw

Highly recommended
tools and supplies:

• Inch-pound and foot-pound
torque wrenches

• Penetrating oil or light
lubricant spray

• Transmission jack (manual
transmission)

1

⁄2" and 3⁄8"

2 96440 v.10.0

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.
Place the transmission in park
(automatic) or reverse (manual), set the
parking brake and securely block the
wheels that are on the ground.

CAUTION:
DO NOT WORK UNDER ANY VEHICLE
SUPPORTED ONLY BY A JACK. SEVERE
INJURY MAY RESULT.

WARNING! The following step
may require the use of a torch and/
or saw. Proper safety equipment
should be used. Failure to use proper
safety equipment may result in
severe injury.

3. From under the vehicle, remove the

factory exhaust system from the catalytic
converter back. Starting at the rear of
the vehicle, remove each component
by either cutting through the pipe near
the clamps or by removing the clamps
and heating the joints with an oxy­acetylene torch to allow crimped pipes
to separate. DO NOT CUT OR DAMAGE
CATALYTIC CONVERTER TUBING
DURING THE REMOVAL PROCESS. To
assist in removal, the T.O.P. should be
cut before the transmission if it is
going to be replaced. Remove the
hanger pins from the rubber hangers
with a pry bar. (Spray lubricant will ease
hanger removal.)

4. Remove the two (2) nuts attaching

the turbine outlet pipe (T.O.P.) to the
catalytic converter inlet. Loosen and

remove the band clamp that attaches
the rear intermediate pipe to the
catalytic converter outlet. Remove
the catalytic converter assembly from
the vehicle. Remove the band-clamp
that attaches the T.O.P. to the
turbocharger and remove the factory
T.O.P. from the vehicle. Retain V-band
clamp for re-assembly.

Note: To assist in T.O.P. removal,
remove the rear engine hoist hook by
removing the two (2) Hex screws and
remove the valve cover heatshield.
The dipstick tube may also be
removed or slightly bent to allow for
T.O.P. removal/installation. Retain all
hardware and parts for reassembly.

For Manual Transmissions only:

transmission will need to be lowered
to allow for removal and installation of
the T.O.P. Using a Transmission Jack,
support the rear of the transmission to
allow working room for the T.O.P. and
remove the rear transmission mount
and crossmember. Remove the Front
drive shaft support bracket from the
cab. Lower the transmission 4-6" and
remove the factory T.O.P.

The transmission may need to be
raised before the Banks T.O.P. is
installed. Install the Banks T.O.P. Raise
the transmission and reinstall drive
shaft bracket, transmission
crossmember and rear transmission
mount. Refer to vehicles owners manual
for factory Torque Specifications.

the

5. Loosely place the factory V-band

clamp on the Banks T.O.P. Install the
Banks T.O.P. to the turbine housing.
Loosely snug the V-band clamp
assuring

Note: Reinstall the engine hoist hook
and valve cover heat shield if
previously removed.

the T.O.P. is aligned properly.

6. The catalytic converter inlet will

need to be trimmed to accommodate

96440 v.10.0 3

Figure 1

General Assembly Diagram

1 Turbine Outlet Pipe (T.O.P.) (1)
2 Front Intermediate Pipe (1)
3 Rear Intermediate Pipe (Crew-Cab Long-bed / Crew-Cab Short-Bed) (1)
4 Extension Pipe (Crew-Cab Long-Bed) (1)
5 Rear Intermediate Pipe (Extended-Cab Long-Bed) (1)
6 Rear Intermediate Pipe (Extended-Cab Short-Bed and Excursion) (1)
7 Rear Intermediate Pipe (Regular-Cab Long-Bed) (1)
8 Banks Monster Muffler (1)
9 Monster Tailpipe (1)
10 Polished 5" Exhaust Tip (1)
11 Exhaust Clamp, 4" (1)*

1

12 Exhaust Clamp, 3
13 Hanger Clamp, Front, Muffler
14 Hanger Clamp, Rear, Muffler
15 Hanger Pin Assembly (1)**
16 Bolt, 8-1.25x30mm (2)**
17 Washer, Flat,
18 Nut, Lock, 8-1.25mm (2)**
19 Spacers, 8mm (2)***
20 Banks Power decals (2)

⁄2" (2)

5

⁄16" (2)**

1

4 96440 v.10.0

12

3

12

11

3

2