Gale Banks Engineering Diesel Performance Specialists Automobile Accessories F250 User Manual

with Installation Instructions  
OwnersManual  
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.2.0  
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. For 2005-06 4-wheel drive  
equipped vehicles only: Remove the  
electronics module near the driver  
side battery shown in Figure 1. The  
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.  
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 Figure 2. Note: Be  
careful not to break the plastic box,  
as it will be re-installed later.  
Figure 2  
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]. For 2005-06  
4-wheel drive equipped vehicles only:  
A small bracket used to mount an  
electronic module will also be  
removed with the plastic battery tray.  
96782 v.2.0  
3
Figure 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  
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. 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: Remove the  
two retaining clips that attach the  
wire harness to the metal battery  
tray.  
16. Remove the driver’s side metal  
battery tray [(3x) 13mm socket].  
Figure 4  
3
17. Drill a 8 inch hole as shown in  
Figure 3.  
18. Reinstall the battery tray as  
shown in Figure 4 with the supplied  
1
2" spacer and longer supplied 8mm  
bolts. Torque the bolts to 12 ft-lbs  
4
96782 v.2.0  
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.2.0  
5
Figure 6 General Assembly Banks Techni-Cooler  
Item Description  
P/N  
Qty  
1
High-Ram Intake Manifold  
2003-04  
42745  
42746  
41326  
94215  
94510  
93038  
91534  
91535  
91110  
91102  
91106  
93606  
92897  
92860  
91890  
91810  
1
1
1
1
1
1
3
1
4
4
2
2
2
2
1
2
2005-06  
2
3
Boost tube, left  
Hose, 3.5”x 3.25”, Black  
Hump Hose, 3” x 3”, Blue  
Gasket, High-Ram Intake  
4
5
1
6
Stud, High-Ram Air Intake M6-1.0 x 4-20 x 4.365  
1
7
Stud, High-Ram Air Intake M6-1.0 x 4-20 x 6.725  
1
8
Nut, Nylock 4”-20  
1
9
Washer, SAE Flat, Zinc 4”  
1
10  
11  
12  
13  
14  
15  
Washer, Thread Sealing 4”-20  
O-Ring. High-Ram  
Hose Clamp, 3.5” Spring Loaded  
Hose Clamp, 3.0” Spring Loaded  
Spacer, Battery Box  
Hex-Bolt, Washer Head, Black 8mm-1.25 x 30mm  
15  
2
14  
8
3
9
10  
9
4
12  
1
5
11  
6
13  
7
6
96782 v.2.0  
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  
1
shorter than the 4"-20 threads on  
the opposite ends of the studs.  
1
21. Using the two 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. Reverse the process to remove  
the nut and repeat for each stud.  
22. 2003 to 2004 vehicles only.  
Remove 0.75" of the split loom near the  
connector shown in Figure 7 to  
provide additional clearance for the  
High-Ram.  
23. Install the supplied o-rings on  
the two driver side studs as shown in  
the exploded view in Figure 8. Slide  
Figure 8  
NYLOCK NUT  
STANDARD WASHER  
THREAD SEALING  
WASHER  
BANKS HIGH RAM  
O-RING  
STUD  
96782 v.2.0  
7
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. Use a  
twisting motion to thread the sealing  
washers over the threaded portion of  
the studs to avoid tearing the seals.  
Install standard flat washers on the  
passenger side studs and on top of  
the thread sealing washers, as shown  
in Figure 8.  
27. Secure the High Ram with (4x)  
1
4"-20 Nylon locking nuts. Torque to  
9 ft-lbs.  
On 2003 to 2004 vehicles: The brake  
line on the driver side may need to  
be slightly bent to provide additional  
clearance for the boost tube.  
32. Re-install the driver’s side  
NOTE: Before slipping the boost tube  
and the corresponding hose, into  
position, ensure that all connection  
ends are clean and free of any oil  
residue and contaminates. Clean all  
connection points with a non-oil  
based solvent such as Acetone,  
Mineral Spirits, Denatured Alcohol or  
Lacquer Thinner. Read and follow the  
manufactures operation instruction  
for non-oil based solvent cleaner.  
battery, battery hold down clamp,  
and plastic battery cover. Torque the  
hold down clamp retaining bolt to 89  
in-lbs. 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.  
On 2005-06 vehicles: One of the  
power steering fluid lines may need  
to be bent to provide clearance for  
the driver side boost tube.  
29. The hose clamps on the High  
Ram must be positioned as shown in  
Figure 9 to avoid contact with the  
hood.  
28. Locate the Banks boost tube,  
connection hose, hump hose and  
supplied hose clamps. Install hoses,  
hose clamps and Banks boost tube  
as shown in Figure 6.  
30. Tighten the hose clamps to 75  
inch-lbs (not ft-lbs!).  
33. For 2005-06 4-wheel drive  
equipped vehicles only: Re-install the  
electronic module near the driver  
side battery. The module is shown in  
Figure 1.  
31. Re-install the plastic driver side  
battery box. Torque the attachment  
bolts to 12 ft-lbs.  
Note: the connection hose should be  
slid firmly against the hose stops  
provided on the High Ram. Allow a  
34. Re-install the air filter assembly  
On 2005-06 4-wheel drive vehicles  
only: Reinstall the electronic module  
mounting bracket that was removed  
with the plastic battery tray.  
1
box and air box front cover.  
minimum ⁄8” air gap between CAC,  
High Ram and boost tubes.  
35. Re-install the driver and  
passenger (+) and (-) battery cables.  
8
96782 v.2.0  
Template 1  
(fan shroud, step 19)  
96782 v.2.0  
9
Notes  
10  
96782 v.2.0  
Notes  
96782 v.2.0  
11  
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  

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