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banks Power Stinger Owner's Manual

Compatible with optional banks iq, 2003-2007 ford power stroke 6.0l turbo-diesel pickups
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Owner' s Manual
with Installation Instructions
Banks Power Pack
®
/Stinger
System
®
Compatible with Optional Banks iQ™
2003-2007 Ford Power Stroke 6.0L
Turbo-Diesel Pickups
THIS MANUAL IS FOR USE WITH SYSTEM 63743, 63745, 63747 & 63748
For iDash 1.8 instructions, see iDash 1.8 manual 97654
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
09/25/18 PN 96824 v.4.0
©2018 Gale Banks Engineering

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  • Page 1 Banks Power Pack ® /Stinger System ® Compatible with Optional Banks iQ™ 2003-2007 Ford Power Stroke 6.0L Turbo-Diesel Pickups THIS MANUAL IS FOR USE WITH SYSTEM 63743, 63745, 63747 & 63748 For iDash 1.8 instructions, see iDash 1.8 manual 97654 Gale Banks Engineering 546 Duggan Avenue •...
  • Page 2 Also Available from Banks Power 03-07 Ford 6.0L Banks iQ System Banks Ram-Air Intake System Banks Brake (P/N 61151-61152) (P/N 42155) (P/N 55467-55468) - 5” touchscreen interface that - Increases your airflow over - Increases the stopping power can control the Banks Diesel stock.
  • Page 3 EGT limiting safety. - Monster Exhaust (single or dual) Banks Bullet Thermocouple - EconoMind Tuner w/ Banks iQ (P/N 66524-66525) - Add a temperature limiting - High-Ram - Adds power safely to your function to your Diesel Tuner - Techni-Cooler System...

  • Page 4: General Installation Practices

    During installation, keep the its mounting location if the work area clean. If foreign debris vehicle will be subjected to high is transferred to any Banks system For ease of installation of your concentrations of sunlight, heat component, clean it thoroughly...

  • Page 5: Table Of Contents

    • Drill motor Section 5 ..... 29 • Tap Handle Mounting and Connecting the Banks iQ • ⁄ ” NPT tap Section 6 .

  • Page 6: Banks Powerpack System

    General Assembly Diagram BANKS POWERPACK SYSTEM 96824 v.4.0...
  • Page 7 96824 v.4.0...

  • Page 8: Section 1

    Section 1 INSTALLATION OF BANKS MONSTER EXHAUST SYSTEM Figure 1a General Assembly Banks Monster Exhaust (Single Tailpipe) Description Part # Qty. Banks Monster Muffler 53800 Turbine Outlet Pipe 2003 (T.O.P.) w/ Resonator 53525 2004-2007 (T.O.P.) w/o Resonator 53537 Front Intermediate Pipe...
  • Page 9 96824 v.4.0...
  • Page 10 Figure 1b General Assembly Banks Monster Exhaust, Split-Dual Description Part # Qty. Banks Monster Muffler 53800 Turbine Outlet Pipe (T.O.P.) 2003 w/ Resonator 53525 2004-07 w/o Resonator 53537 Front Intermediate Pipe 53526 Rear Intermediate Pipe (Crew-Cab Short-Bed) 53557 (Extended-Cab Long-Bed)
  • Page 11 96824 v.4.0...
  • Page 12 Proper safety Loosely place the factory V-band inlet, but do not tighten at this time. equipment should be used. clamp on the Banks T.O.P. Install the Place a supplied 3 ⁄ ” clamp Failure to use proper safety Banks T.O.P.
  • Page 13 Insert the hanger pin into the vehicle’s rubber grommet. Install the inlet of the Banks Monster muffler to the intermediate pipe. Install the dual pin rear hanger clamp onto the outlet of the Monster muffler with the hanger pins on the inside, facing the muffler.
  • Page 14 CLAMP rubber grommet (see Figure 4). For Short Bed models, Install a 4” clamp on the inlet of the Banks Monster muffler. Install the Banks Monster Muffler onto the intermediate pipe outlet and lightly tighten the 4” clamp / hanger clamp.
  • Page 15 VENT HOSE & BRAKE LINE BANKS Tighten the exhaust clamps as PASSENGER SIDE necessary. Whenever possible, tack- TAILPIPE welding slip connections to prevent disengagement is recommended. The Banks Monster Exhaust installation is now complete. -END, SECTION 1- Figure 7 96824 v.4.0...

  • Page 16: Section 2

    Spacer, Battery Box 91890 Hex-Bolt, Washer Head, Black 8mm-1.25 x 30mm 91810 Hose clamp, 3.5” Spring Loaded 92897 Hose clamp, 2.5” Spring Loaded — * These are stock components that will be re-used with the Banks Techni-Cooler System 96824 v.4.0...
  • Page 17 Figure 9 Note: If installing a Stinger System, proceed to Section 3. REMOVE STOCK COMPONENTS Note: Save all factory components and fasteners that are removed for re-installation with the exception of: Charge Air Cooler (CAC), Intake Elbow, Boost Tubes, and CAC Hose Connections.
  • Page 18 Figure 12 For 2005-07 4-wheel drive equipped vehicles only: Remove the electronics module near the driver side battery shown in Figure 13. 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.
  • Page 19 Remove the stock CAC. MODIFICATIONS TO MAKE ROOM FOR THE BANKS TECHNI-COOLER SYSTEM For 2005-07 4-wheel drive equipped vehicles only: Remove the two retaining clips that attach the wire harness to the metal battery tray.
  • Page 20 39 of this manual, to clear the larger diameter boost tubes. Trim the fan shroud as shown in Figure 18 using Template 2 in Page 39 of this manual, to clear the Banks High Ram. Note: 2005-07 vehicles require a different trim to fan shroud, use appropriate template.
  • Page 21 ⁄ ”-20 threads on rubber air deflectors removed from the opposite ends of the studs. Torque the eight upper radiator the stock CAC on the Banks CAC. Use support bolts to 22 ft-lbs. Using the two ⁄ ”-20 nuts the supplied zip tie mounts to affix provided, tighten the High Ram studs the air deflectors to the Banks CAC.
  • Page 22 Lacquer Thinner. Read and follow the WASHER manufactures operation instruction for non-oil based solvent cleaner. Install the driver and passenger BANKS HIGH RAM side boost tubes and connection hoses as shown in Figure 8 The connection hoses should be slid firmly against the hose stops...

  • Page 23: Section 3

    Section 3 THERMOCOUPLE INSTALLATION Figure 22 Remove the driver side exhaust manifold. Drill a ⁄ ” hole in the driver side exhaust manifold at the location shown in Figure 23. Tap the hole for a ⁄ ” NPT thread. Check the thread depth as you tap by periodically removing the tap and screwing the pipe coupling into the tapped hole.

  • Page 24: Section 4

    Section 4 BANKS ECONOMIND DIESEL TUNER INSTALLATION Banks EconoMind Diesel Tuner For 2005-07 Model years, slide Disconnect the middle connector Installation EconoMind shield onto crossover from the PCM by opening the over cable. center retaining clamp as shown in Make sure the previously removed Figure 29.
  • Page 25 Figure 27 Plug the EconoMind MAP connector into the MAP sensor. Plug the factory MAP connector into the EconoMind MAP wiring harness. Route the harness from the EconoMind to the MAP sensor as shown in Figure 31. Use the supplied zip ties to secure the MAP harness to the factory harness.
  • Page 26 Figure 30 Note: If you are not installing the optional Banks iQ then coil up and secure cable with the RJ12 (telephone style) connector end. Remove the fuse box cover, located in the cabin compartment. Locate the mini-fuse #22 and remove.
  • Page 27 Figure 33 2005-07 model year vehicles only: Remove the adhesive backing from two (2) dual-lock fasteners and attach them to the EconoMind shield and attach the other end to the top of the fuse box. Remove the adhesive backing from the (2) dual-lock fasteners on the back of the EconoMind Diesel Tuner and affix the tuner to: 2003-04 model year vehicles: The...
  • Page 28 Figure 37 Figure 38 96824 v.4.0...

  • Page 29: Section 5

    If not installing the optional Banks iQ, window mount to the corresponding If applicable, remove the side access slots on the bottom of Banks iQ first skip to Section 6. panel to help route wiring to the top of the dash. See Figure 41.
  • Page 30 Figure 40 Suggested Mounting location for Banks iQ WARNING: THE CHARGING CABLE CONNECTED TO THE BANKS iQ IS DESIGNED TO SUPPLY A CONSTANT LOW-VOLTAGE POWER SOURCE (+5VDC) TO THE BANKS iQ AND IS “LIVE” AS LONG AS THE SYSTEM’S OBD II INTERFACE CABLE OR...
  • Page 31 Figure 43 Figure 44 Banks iQ System Figure 45 Banks Bridge Module 96824 v.4.0...

  • Page 32: Section 6

    Section 6 INSTALLATION OF THE POWER LEVEL SELECTOR SWITCH Not needed if Banks iQ will be Figure 46 Removal of the stereo (2003-04 model year vehicles only) installed. Please proceed to Section Caution: Do not use excessive force when working on plastic parts.
  • Page 33 Uni-bit, center the bit onto the ⁄ ” drill location on the template and Remove the nut and internal Align the Banks power level slowly drill through. Using a ⁄ ” drill tooth washer from the power level switch label on the previously drilled bit, center and drill through the ⁄...

  • Page 34: Section 7

    Gauges on the EconoMind wiring additional gauges are available harness. See Figure 26. Connect the 4-pin connector through Gale Banks Engineering. of each gauge into the back of its Install the DynaFact boost and Using the panel as a template, corresponding gauge.

  • Page 35: Section 8

    Start the truck and allow the level, depends on the driving cycle. refer to the Banks iQ Software & engine to reach normal operating Installation Kit, Owners Manual for The transmission will quickly adapt temperature.
  • Page 36 Figure 54 Diagnosing EconoMind error codes without Banks iQ If you feel that your Banks EconoMind Diesel Tuner is not functioning properly, some diagnostics can be performed. Your EconoMind Diesel Tuner is equipped with diagnostic features that will detect and display certain errors.
  • Page 37 Check the 46-Pin connectors. Reset EconoMind Diesel Tuner by turning key on and off . output signal Check the 46-Pin connectors. Reset EconoMind Diesel Tuner by turning key Internal Module Malfunction on and off . If problem persists, call Gale Banks Engineering Tech Support. 96824 v.4.0...

  • Page 38: Removal Of The Economind Diesel Tuner

    ‘In-Cab Cable’ and gently pull -END, SECTION 10- the cable back through the firewall. Re-connect the vehicle’s 46-pin connector back into the middle connection on the PCM. Section 11 PLACEMENT OF THE BANKS POWER DECAL Figure 55: Placement of the Banks decals 96824 v.4.0...
  • Page 39 Template 1 (fan shroud, step 34) Template 2 (fan shroud, step 35) CUT LINE BOOST TUBE FAN SHROUD TEMPLATE FRONT 96824 v.4.0...
  • Page 40 This page left blank intentionally 96824 v.4.0...
  • Page 41 Template 3: Templates for locating the power level switch on the dash panel. 2003-04 model year vehicles only Template 4: Templates for locating the power level switch on the dash panel. 2005-07 model year vehicles only 96824 v.4.0...
  • Page 42 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...

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