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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
(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
©2006 Gale Banks Engineering 03/
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General Installation Practices the topsides. When raising the front of the vehicle, put the transmission in Dear Customer, park (automatic) or reverse (manual), If you have any questions set the parking brake, and block the concerning the installation of rear wheels. When raising the back of your Banks Power System, the vehicle, be sure the vehicle is on please call our Technical Service level ground and the front wheels are Hotline at (888) 839-2700 blocked securely. Caution! Do not use betwe
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Monster Exhaust System Installation remove the band clamp that attaches 1. Disconnect the negative (ground) the rear intermediate pipe to the cable from the battery (if there is more catalytic converter outlet. Remove than one battery, disconnect both the catalytic converter assembly from negative cables). Secure the cable so the vehicle. Remove the band-clamp it cannot accidentally come in contact that attaches the T.O.P. to the with the post. turbocharger and remove the factory 2. Raise the
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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)
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* Crew-Cab Long-Bed models contain two (2) 4" exhaust clamps ** Crew-Cab Short-Bed only *** Long-Bed only 10 19 14 15 9 16 8 18 17 13 4 11 20 5 6 7 96440 v.10.0 5
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the Banks exhaust system. Be careful about 7" rear of the inlet flange). Using not to trim an excessive amount of a reciprocating saw or equivalent, tubing. Be sure to wear proper vertically cut and remove 7" from the safety equipment. converter outlet tubing (see Figure 2). IMPORTANT: Diesel catalysts may B) Install the supplied Banks front become plugged with soot which intermediate pipe onto the previously can restrict exhaust flow, impeding installed Banks T.O.P. Loosely install performance
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the intermediate pipe and snug a muffler hanger location (see Figure 3). supplied 4" clamp onto the connection. Note: spacers are to be installed between Note: Exhaust clamps should be the hanger pin and the inside of the frame placed at the beginning of the slot and rail. Torque factory nuts to 20 ft-lbs. evenly tightened. 10. For crew-cab short-bed models, 9. For crew-cab long-bed, extended-cab it is necessary to replace the factory- short bed, and extended-cab long-bed installed frame-mounte
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C) Reinstall the rubber hanger onto the 13. Route the tailpipe over the rear mounted hanger pin assembly. axle housing and into the muffler outlet. Install the tailpipe hanger pin into the 11. Install the single pin front hanger corresponding rubber hanger. Loosely clamp onto the rear of the intermediate snug the 4" hanger clamp onto the pipe with the hanger pin on the inside muffler outlet. facing the muffler. Insert the hanger pin into the vehicle's rubber grommet. 14. Install the 5" Monster t
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1 fully inserted (+/- ⁄4 inch) and that all the Ford badging on your truck. Use the mount hangers are in the forward provided measurements (see Figure 5) position (see Figure 4). to position the logos for a clean factory look. 16. Remove the protective covering from the tailpipe tip. Caution: The 18. Re-connect negative battery protective covering may ignite and cable(s). Start the engine and listen burn if not removed prior to running for exhaust leaks. Tighten the exhaust the engine. clamps a
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10 96440 v.10.0 Parts List—Ford Power Stroke Monster Exhaust T.O.P. System (Build Date 9/03 & Earlier) Std. Cab LB Ext. Cab SB Crew Cab SB Ext. Cab LB Crew Cab LB Excursion 137" WB 141" WB 156" WB 158" WB 172" WB P/N Description 48761 48761 48761 48761 48761 48761 53525 2003 T.O.P w/Resonator 1 1 1 1 1 1 53526 Front Intermediate Pipe 1 1 1 1 1 1 52470 Exhaust Clamp, 4" 1 1 1 1 1 1 52468 Exhaust Clamp, 3.5" 1 1 1 1 1 1 96440 Owners Manual 1 1 1 1 1 1 T.O.P. System (Build Date 10/03 & Later) 48781
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96440 v.10.0 11 Monster Exhaust System Std. Cab LB Ext. Cab SB Crew Cab SB Ext. Cab LB Crew Cab LB Excursion 137" WB 141" WB 156" WB 158" WB 172" WB P/N Description 48755 48756 48757 48758 48759 48760 53800 Monster Muffler 1 1 1 1 1 1 53512 Tailpipe 1 1 1 1 1 53536 Tailpipe (Excursion) 1 52383 Tailpipe Tip 1 1 1 1 1 1 53453 Hanger, Clamp, Front Muffler 1 1 1 1 1 53454 Hanger, Clamp, Rear Muffler 1 1 1 1 1 53498 Hanger Clamp, Front, Muffler (Excursion) 1 53499 Hanger Clamp, Rear, Muffler (Excursi
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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
