Gale Banks Engineering F450, F350, F250, F550 User Manual

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

43

7

1

-

9600 • F

(626) 969

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

bankspower.com

©2006 Gale Banks Engineering

-

ax (626) 33

888) 839-2700

(

4

10/30/06 PN 96782 v

.2.0

Dear Customer,

f you have any questions

I

oncerning the installation of

c
your Banks Techni-Cooler, 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

ontact our Customer Service

c
Department at [phone].

Thank you.

Tools Required:

• Drive ratchet

• Ratchet extension

• Inch and metric deep sockets

• Pliers

• Phillips and flat blade screwdrivers

• Inch and metric open end wrenches

Recommended tools:

• Foot-pound torque wrench

• Inch-pound torque wrench

General Installation
Practices

1. Before starting work, familiarize

yourself with the installation
procedure by reading all of the
instructions.

2. Throughout this manual, the left

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

3. Disconnect the negative (ground)

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

4. Route and tie wires and hoses a

minimum of 6” away from exhaust
heat, moving parts and sharp edges.

”

Clearance of 8
recommended where possible.

or more is

5. When raising the vehicle, support

it on properly weight-rated safety
stands, ramps or a commercial hoist.
Follow the manufacturer’s safety

recautions. Take care to balance the

p

ehicle to prevent it from slipping or

v

alling. When using ramps, be sure

f

he front wheels are centered

t
squarely on the topsides. When
raising the front 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,

e sure the vehicle is on level ground

b

nd the front wheels are blocked

a
securely.

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 floor

6. 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.

2 96782 v.2.0

Figure 1. Electronic module near the driver side battery on 2005-06 4-wheel
drive equipped vehicles

Figure 2

emove Stock Components

R

1. Remove the (+) and (-) battery

cables from both the drivers and

assenger side batteries.

p

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. For 2005-06 4-wheel drive

equipped vehicles only:

electronics module near the driver
side battery shown in
retaining tab for the module can be
pried back with a flat blade
screwdriver as shown in the figure.
After the tab is depressed, the
module can easily be pulled away
from it's mounting bracket.

Remove the

Figure 1. The

6. Remove driver’s side plastic

battery cover. There are tabs at the
front and back of the cover that need
to be depressed to remove the cover,
as shown in

careful not to break the plastic box,
as it will be re-installed later.

Figure 2. Note: Be

7. Remove the driver’s side battery

hold down clamp (8mm socket).

8. Remove the driver’s side battery.

WARNING: When lifting a battery,
excessive pressure on the end
walls could cause acid to spew
through the vent caps, resulting in
personal injury. Lift with a battery
carrier or with hands on opposite
corners. Failure to follow these
instructions may result in
personal injury.

9. Remove the wire harness plastic

retaining clip on the back of the
plastic battery box.

10. Remove the plastic battery box

[(4x) 13mm socket].

4-wheel drive equipped vehicles only:

A small bracket used to mount an
electronic module will also be
removed with the plastic battery tr

For 2005-06

ay.

96782 v.2.0 3

11. Locate the driver side boost

tube. Loosen the hose clamps and
remove the boost tube, hose clamps
and hose (if applicable) from engine
compartment and set aside. These

arts will not be reused.

p

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

anifold.

m

13. Remove the stock intake elbow

and gasket.

14. Cover the inlet to the intake

manifold to prevent debris from
getting into this area.

Modifications to make room for
the Banks Techni-Cooler System

15. For 2005-06 4-wheel drive

equipped vehicles only:

two retaining clips that attach the
wire harness to the metal battery
tray.

Remove the

16. Remove the driver’s side metal

battery tray [(3x) 13mm socket].

17. Drill a

Figure 3.

3

⁄8 inch hole as shown in

18. Reinstall the battery tray as

shown in

1

⁄2" spacer and longer supplied 8mm

bolts. Torque the bolts to 12 ft-lbs

Figure 4 with the supplied

Figure 3

Figure 4

4 96782 v.2.0