Owner’sManual with Installation Instructions Banks Monster Exhaust System ® 2003-2007 Ford Power Stroke 6.0L Turbo-Diesel F450/F550 Trucks, Cab & Chassis THIS MANUAL IS FOR USE WITH SYSTEMS 47273-47292 Gale Banks Engineering 546 Duggan Avenue • Azusa, ca 91702 (626) 969-9600 • Fax (626) 334-1743 Product Information & Sales: (800) 438-7693 bankspower.com ©2008 Gale Banks Engineering 08/22/08 PN 96441 v.3.
General Installation Practices Dear Customer, If you have any questions concerning the installation of your Banks Power System, please call our Technical Service Hotline at (888) 839-2700 between 7:00 am and 5:00 pm (PT). If you have any questions relating to shipping or billing, please contact our Customer Service Department at (888) 839-5600. Thank you. 1.
Monster Exhaust System Installation 1. Disconnect the negative (ground) cable from the battery (if there is more than one battery, disconnect both negative cables). Secure the cable so it cannot accidentally come in contact with the post. 2. Raise the vehicle and support it securely with properly weight-rated safety stands, ramps or a commercial hoist. Take care to balance the vehicle to prevent it from slipping or falling. When using ramps, be sure the wheels are centered squarely on the topsides.
Figure 1 General Assembly Diagram T.O.P System (Build Date 9/03 & Earlier) T.O.P System (Build Date 10/03 & Later) Item# Description Item# Description 1a T.O.P w/Resonator 1b T.O.P w/ 0ut Resonator 2 Front Intermediate Pipe 2 Front Intermediate Pipe 8 Exhaust Clamp, 4” 8 Exhaust Clamp, 4” 9 Exhaust Clamp, 3.5” 9 Exhaust Clamp, 3.5” Item# Description 3a EC 162” WB - Rear Interm. Pipe (Kit 47273) 3b RC 165” WB - Rear Interm. Pipe (Kit 47274) 3c CC 176” WB - Rear Interm.
7 6 10 5 4 8 8 6a 11 96441 v.3.
not to trim an excessive amount of tubing. Be sure to wear proper safety equipment. IMPORTANT: Diesel catalysts may become plugged with soot which can restrict exhaust flow, impeding performance. Inspect the converter by shining a powerful flashlight into the inlet. Observe the light through the other end of the converter. The full circle of the flashlight should be visible without any blockage in the gridwork of the catalyst. If excessive soot is observed, the catalyst may need to be cleaned.
10. Install a 4” exhaust clamp onto the Banks Monster Muffler inlet. Connect the muffler inlet onto the rear of the extension pipe. Install the 4” muffler clamp onto the Monster muffler outlet such that the hanger pins are towards the front of the vehicle. Install the hanger pins into the vehicle’s rubber insulators. 11. Route the tailpipe over the rear axle housing and into the muffler outlet. Install the tailpipe hanger pin into the corresponding rubber hanger.
the provided measurements (see Figure 5) to position the logos for a clean factory look. 16. Re-connect negative battery cable(s). Start the engine and listen for exhaust leaks. Tighten the exhaust clamps as necessary. Whenever possible, tack-welding slip connections to prevent disengagement is recommended. Banks Monster Exhaust installation is now complete. Figure 4 8 94441 v.3.
Figure 5 96441 v.3.
94441 v.3.0 53526 52470 52465 2 8 9 96440 53537 1b 53525 P/N 1a Item# 1 48761 T.O.P System (Build Date 9/03 & Earlier) Owners Manual Exhaust Clamp, 3.5” Exhaust Clamp, 4” Front Intermediate Pipe 1 1 1 1 T.O.P w/out Resonator T.O.P w/Resonator Description 1 1 1 1 1 48781 T.O.
96441 v.3.0 11 47287 47288 47289 Reg. Cab Crew Cab 165” WB 176” WB Storage Boxes 47280 47281 47290 47282 1 53546 53547 52383 52470 52468 53544 96009 6 6a 7 8 9 10 11 96441 53800 5 53541 Owners Manual Banks Power Decal Hanger Clamp, Muffler Exhaust Clamp, 3.
Gale Banks Engineering 546 Duggan Avenue • Azusa, ca 91702 (626) 969-9600 • Fax (626) 334-1743 Product Information & Sales: (800) 438-7693 bankspower.
