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
(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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