banks Monster User manual

10/29/08 PN 96572 v.2.0
Banks Monster®
Sport Exhaust
System
Late 1999-2003 Ford Power Stroke 7.3L
Turbo-Diesel F-250/F-350 Trucks Without
Factory Installed Catalytic Converter
THIS MANUAL IS FOR USE WITH SYSTEM 48789
Gale Banks Engineering
546 Duggan Avenue • Azusa, CA 91702
[phone] • Fax [phone]
Product Information & Sales: [phone]
Customer Support: [phone]
Installation Support: [phone]
bankspower.com
©2008 Gale Banks Engineering
Owner’sManual
with Installation Instructions

Dear Customer,
If you have any questions
concerning the installation of
your Banks Monster Exhaust
System, please call our Technical
Service Hotline at [phone]
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. For ease of installation of your
Banks system, familiarize yourself with
the procedure by reading the entire
manual before starting work.
2. The exploded view (pages 4-5)
provides only general guidance. Refer
to each step and section diagram in
this manual for proper instruction.
3. Throughout this manual, the
left side of the vehicle refers to the
driver’s side, and the right side to the
passenger’s side.
4. Disconnect the ground cable from
the battery (or batteries, if there are
two) before beginning work.
5. Route and tie wires and hoses a
minimum of 6” away from exhaust
heat, moving parts and sharp
edges. Clearance of 8” or more is
recommended where possible.
6. When raising the vehicle, support
it on properly weight-rated safety
stands, ramps or a commercial hoist.
Follow the manufacturer’s safety
precautions. Take care to balance the
vehicle to prevent it from slipping or
falling. When using ramps, be sure the
front wheels are centered squarely on
the topsides; put the transmission in
park; set the hand brake; and place
blocks behind the rear wheels.
Caution! Do not use floor jacks to
support the vehicle while working
under it. Do not raise the vehicle
onto concrete blocks, masonry
or any other item not intended
specifically for this use.
7. During installation, keep the work
area clean. Do not allow anything
to be dropped into intake, exhaust,
or lubrication system components
while performing the installation, as
foreign objects will cause immediate
turbocharger and/or engine damage
upon start-up.
Note: Prior to beginning any work,
please verify the build date of your
vehicle.
Certain steps in this manual are
model-year specific, so be sure to read
each step carefully before performing
any work.
General Installation Practices
296572 v.2.0

Tools Required:
• 1⁄2” and 3⁄8” drive ratchets with inch
and metric sockets and 1⁄2” and 3⁄8”
drive extension
• Inch and metric combination or
open-end wrenches
• Standard screwdriver
• Clean shop towels or rags
• Pry-bar
• Reciprocating saw
• Inch-pound and foot-pound
torque wrenches
• Penetrating oil or light
lubricant spray
96572 v.2.0 3

General Assembly
Figure 1
Item Description P/N QTY
1 Intermediate Pipe 53456 1
*2 Extension Pipe Kit, CCSB 53516 1
*3 Extension Pipe Kit, ECLB 53517 1
*4 Extension Pipe Kit, CCLB 53518 1
5 Monster Muffler 53810 1
6 Tailpipe 53465 1
73.5” Exhaust Clamp, Band Style 52467 1
*8 4” Exhaust Clamp 52470 1
9Hanger Clamp, Mufer Front 53453 1
10 Hanger Clamp, Mufer Rear 53454 1
* Extension Pipe Kits contain one (1) 4” exhaust Clamp
5
10
9
6
13
496572 v.2.0

7
* 8
4
2
3
1
12
11
14
96572 v.2.0 5
Item Description P/N QTY
**11 Frame Mounted Hanger 53519 1
**12 Bolt, 8MM X 1.25 X 30MM Hex 91789 2
13 Monster Tailpipe Tip (Optional) 52383 1
14 Banks Urocal 96009 2
** Extension Pipe Kit 53517 ONLY
*
**
**
*
*

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. Place the transmission in park
(automatic) or reverse (manual), set the
parking brake and securely block the
wheels that are on the ground.
CAUTION: Do not work under any
vehicle supported only by a jack.
Severe injury may result.
WARNING! The following step
may require the use of a torch and/
or saw. Proper safety equipment
should be used. Failure to use
proper safety equipment may
result in severe injury.
3. From under the vehicle, remove
the factory exhaust system from the
factory front intermediate pipe. See
Figure 2. Starting at the rear of the
vehicle, remove each component by
either cutting through the pipe near
the clamps or by removing the clamps
and heating the joints with an Oxy-
Acetylene torch to allow crimped
pipes to separate.
DO NOT CUT OR DAMAGE
CATALYTIC CONVERTER TUBING
DURING THE REMOVAL PROCESS.
Remove the hanger pins from the
rubber hangers with a pry bar. (Spray
lubricant will ease hanger removal.)
4. Place a 31⁄2” clamp on the end of
the factory head pipe
5. For Super-cab short-bed: Install
the supplied intermediate pipe.
For Crew-cab short-bed: Install the
intermediate pipe. Place a 4” clamp on
the end of the intermediate pipe and
install the extension pipe kit (P/N
53516).
Monster Exhaust System Installation
Figure 2
696572 v.2.0
Remove Factory
Tailpipe, Muffler, and
rear Intermediate
pipe.
Do Not remove
Factory Head pipe and
Front Intermediate
pipe.

For Super-cab long-bed: Remove
the rear frame mounted hanger (see
Figure 3) and install the supplied
frame mounted hanger in its place,
using the two 8mm x 30mm hex bolts
supplied and re-using the two 8mm
nuts previously removed. Install the
intermediate pipe. Place a 4” clamp on
the end of the intermediate pipe and
install the extension pipe kit (P/N
53517).
For Crew-cab long-bed: Install
the rear intermediate pipe. Place
a 4” clamp on the end of the rear
intermediate pipe and install the
extension pipe kit (P/N 53518).
6. Install the single pin front hanger
clamp onto the intermediate pipe with
the hanger pin on the inside facing the
muffler. Insert the hanger pin into the
vehicle’s rubber grommet.
7. Install the inlet of the Banks
Monster muffler onto 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. Insert the
two hanger pins into the vehicle’s
rubber grommets. Orient the muffler
such that the Banks logo is visible
from the passenger side.
8. Install the tailpipe into the outlet of
the Monster muffler. Insert the hanger
pin on the tailpipe into the vehicles’s
rubber grommet.
Note: If installing optional tailpipe
tip, cut off 4” from the tailpipe outlet
before installing the tailpipe into Banks
Monster Muffler. See Figure 4.
Figure 3- For Extension Pipe Kit (P/N 53517)
96572 v.2.0 7

If not installing the optional Banks
Monster Tailpipe Tip, Skip to
step 10.
9. Insert the optional tailpipe tip
over the tailpipe outlet. Adjust the tip
past the edge of the body or where
aesthetically pleasing. Torque the band
clamp to 35 ft-lb.
10. Remove protective wrapping from
tailpipe tip.
11. Position all the exhaust
components such that all the hanger
pins are parallel with the frame pins
and all exhaust tubing is located
properly. Lightly tighten the clamps
to maintain position. The tailpipe tip
should be positioned 1-11⁄2 “ below
the bottom edge of the fender. All
hangers should be hanging slightly
forward to allow for heat expansion of
the exhaust tubing (see Figure 5).
12. With everything positioned
properly, begin to tighten the clamps
starting with the ones closest to the
turbo and working your way back.
Torque all clamps to 35 ft-lbs.
13. Your system includes two Banks
Power logos that have been designed to
compliment the Ford badging on your
truck. We have provided measurements,
which will allow you to place these
logos in a position that gives a clean
factory look. See Figure 6.
14. The Monster Exhaust installation
is now complete.
Figure 4- For installation of Optional Tailpipe Tip
896572 v.2.0

Figure 5- Allow Space for Heat Expansion
96572 v.2.0 9

Figure 6- Logo Placement
10 96572 v.2.0

Notes
96572 v.2.0 11

Gale Banks Engineering
546 Duggan Avenue • Azusa, CA 91702
[phone] • Fax [phone]
Product Information & Sales: [phone]
Customer Support: [phone]
Installation Support: [phone]
bankspower.com