Owner’sMawith Installationnu Instructionsal

Banks Ram-Air® System

2008-2010 Ford Power 6.4L Turbo Diesel F250/F350/F450 Trucks

THIS MANUAL IS FOR USE WITH SYSTEM 42185 & 42185-D

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

©2014 Gale Banks Engineering 08/25/14 PN 96496 v.7.0 Also Available from Banks Power

Banks iQ System Banks Exhaust Brake - 5” touchscreen interface that can (P/N 55469) control the Banks Diesel Tuner and/or - Increases the stopping power of SpeedBrake on the fly. your truck and extends the service - Interchangable gauge display, read life of your brakes and clear codes, monitor engine diagnostics, log data, time your Banks SpeedBrake vehicles runs and much more. (P/N 55464) - Allows for controlled hill decent at Banks Monster® a user defined vehicle speed. Single & Dual (P/N 49780-49787) - Increases exhaust flow, cuts Banks Diesel Tuner backpressure, lowers exhaust gas Six-Gun (P/N 63907) temperatures (EGTs) and increases - Adds power safely to your vehicle power. - Engine and transmission safeguards - Change power levels on-the-fly Banks Techni-Cooler® System (P/N 25984) AutoMind Programmer - Provides increased air flow to the (P/N 66110) engine by increasing air density for - Contains Banks tunes that boost more increased power, lower EGTs your vehicles HP, Torque and MPG. and improved fuel economy. - Displays a host of critical engine functions - Provides “service technician” diagnostic capabilities - Has upgradeable functionality, so it will never be out of date

For More Information please call (888) 635-4565 or Visit us online @ www.bankspower.com

2 96496 v.7.0 Six-Gun Bundle Big Hoss Bundle (P/N 46652-46655) (P/N 46656-46659) Contains: Contains: - Monster Exhaust (single and dual) - Monster Exhaust (single and dual) - Ram-Air Intake - Ram-Air Intake - Six-Gun Tuner w/ Banks iQ - Six-Gun Tuner w/ Banks iQ - Techni-Cooler

96496 v.7.0 3 General Installation Practices

Dear Customer, : Do not use floor If you have any questions jacks to support the vehicle while concerning the installation of working under it. Do not raise your Banks Ram-Air System, the vehicle onto concrete blocks, please call our Technical Service masonry or any other item not Hotline at (888) 839-2700 intended specifically for this use. between 7:00 am and 4:00 pm (PT). If you have any questions : The Banks Oiled relating to shipping or billing, Ram- comes pre-oiled please contact our Customer and no oiling is necessary for Service Department at initial installation. Service the (888) 839-5600. filter as specified in the Ram- Thank you. Air Filter Cleaning Instructions Section of this manual.

1. For ease of installation of your Banks Ram-air intake system, Tools Required: familiarize yourself with the procedure • Standard and #3 Phillips head by reading the entire manual before screwdrivers starting work. This manual contains 16 pages of copy, illustrations and • Clean shop towels or rags parts listing. If any pages are missing • 1⁄4” and 5⁄16” nut drivers from this manual please call Gale Banks Engineering immediately for a replacement. Table of Contents 2. The view of the Ram-Air assembly Section 1 ...... 5 (page 5) provides only general General Assembly guidance. Refer to each step and section diagram in this manual for Section 2 ...... 6 proper instruction. Ram-Air Installation 3. Throughout this manual, the Section 3 left side of the vehicle refers to the Oiled Air Filter Cleaning Instructions .14 driver’s side, and the right-side to the passenger’s side. Dry Air Filter Cleaning Instructions . 15 4. Route and tie wires and hoses a minimum of 6 inches away from exhaust heat, moving parts and sharp edges. Clearance of 8 inches or more is recommended where possible. 5. During installation, keep the work area clean. If foreign debris is transferred to any Banks system component, clean it thoroughly before installing.

4 96496 v.7.0 Section 1 GENERAL ASSEMBLY

Figure 1

Item Component # Description Qty 1 42186 HOUSING, RAM-AIR FILTER 1 2 42187 COVER, RAM-AIR HOUSING 1 3 42188/42188-D AIR FILTER ELEMENT, RAM-AIR SYSTEM 1 4 42189 INTAKE TUBE, RAM-AIR SYSTEM 1 5 92904 HOSE CLAMP, #104 1 6 93071 GASKET, MAF SENSOR 1 7 91242 MACHINE SCREW, TRUSS HEAD, PHILLIPS 5⁄16”-18 X 1 1⁄4” 2 8 91226 MACHINE SCREW, TRUSS HEAD, PHILLIPS, 5⁄16”-18 X 3⁄4” 2 9 91719 MACHINE SCREW, TRUSS HEAD, PHILLIPS, #6-32 X 1⁄2” 2 10 92987 Torx Bit, T20-1/4” Drive, Tamper Proof Screw Style 1 11 96009 Urocal, Banks Power, Small-Red, Black & Silver 2

96496 v.7.0 5 Section 2 RAM-AIR INSTALLATION

Use the Bill of Materials Chart and 3. Remove the restriction gauge by the General Assembly Drawing to gently twisting and pulling it out of reference component nomenclature the rubber grommet. See Figure 4. and location. Use caution when Remove the rubber grommet. These working in the engine compartment. will be re-used later. Make sure the engine has been OFF for several hours and cool. 4. Locate the MAF sensor connector. Slide the connector lock back and You are about to install the Banks press the release tab while carefully Ram-Air Intake System. Read and removing the MAF connector. Set it follow all steps before working on the aside. vehicle. Some components from the stock air intake system will remain 5. Remove the warm air intake hose in service. Take care when removing from the air cleaner housing (Figure stock air intake components to not 5). damage them. 6. Gently pry the MAF wiring harness 1. Loosen the hose clamp on the clip loose from the air filter housing air cleaner bellows located next to with a bladed screwdriver (Figure 6). the Mass Air Flow (MAF) sensor. See 7. Remove the MAF sensor Torx (T-20) Figures 2 and 3. screws using the supplied Banks Torx 2. Press and hold the air filter tool bit. restriction gauge’s release tab while 8. Carefully remove the MAF sensor removing the connector. and set aside. The MAF sensor will be re-used later. Figure 2

6 96496 v.7.0 Figure 3

Figure 4

96496 v.7.0 7 Figure 5

Figure 6

8 96496 v.7.0 9. Push the air cleaner bellows away CAUTION: Filter may come loose from the air filter housing while pulling at connection point due to oil up on the MAF side of the air filter. Lift residue. Clean the air filter and remove the air filter housing in the connection points with a non-oil direction shown in Figure 7. based solvent such as Acetone, Mineral Spirits, Denatured 10. Locate the supplied Banks MAF Alcohol, or Lacquer Thinner. Read sensor gasket. Install the supplied and follow the manufacture’s gasket under the MAF sensor. operation instruction for non-oil 11. Install the MAF sensor to the based solvent cleaner. Be careful Banks Intake Tube using the supplied not to apply cleaner to cotton screws. Make sure the MAF sensor filter media or damage to media connection is on the same side as may result. where the restriction gauge will go. 13. Install the restriction gauge’s Note: Do not over tighten the screws. rubber grommet to the Banks Intake tube. 12. Attach the Banks Air Filter Element to the Banks Intake Tube with 14. Install the Banks Ram-Air Filter the supplied hose clamp. An audible Housing. Line up the fresh air intake snap should be heard when installing with the matching opening on the the Filter to the Tube. Tighten to 44 Banks Ram-Air Filter Housing (Figures lb-in (5 Nm). 8, 9). The three feet on the bottom of the Filter Housing will go into the

Figure 7

96496 v.7.0 9 Figure 8

Figure 9

10 96496 v.7.0 rubber isolators in the support bracket. longer Screws go on the engine side Make sure to push the Filter Housing (Figure 13). Tighten the Screws with a all the way down into the rubber #3 Phillips screwdriver. isolators. Note: Take care not to over tighten the 15. Install the Banks Intake Tube into Screws and damage the Housing. the air cleaner bellows as shown in Re-install the restriction gauge Figure 10. 19. and re-attach it’s connector. Twist the Banks Intake Tube 180º 16. Re-attach the MAF connector to as shown in Figures 11, 12. Make 20. the MAF sensor. Slide it’s connector sure the bellows fully seat against lock into the locked position. the stop on the Banks Intake Tube. The Intake Tube tabs should line up 21. Tighten the air filter bellows’ hose with the Filter Housing. Be careful clamp to 44 lb-in (5 Nm). not to damage the MAF sensor while You have successfully completed twisting. 22. the installation of the Banks Ram-Air 17. Insert the warm air intake tube Intake system. See Figure 14. Make into the Banks Ram-Air Housing Cover. sure to go over all hose clamps for Install the Housing Cover onto the tightness and connectors for a secure Filter Housing. fit. 18. Install the supplied Phillips Truss -END, SECTION 2- Head Screws into the cover. The

Figure 10

96496 v.7.0 11 Figure 11

Figure 12

12 96496 v.7.0 Figure 13

Figure 14

96496 v.7.0 13 Section 3 AIR FILTER CLEANING INSTRUCTIONS

OILED AIR FILTER ONLY and does not drive it into the filter. 5. DRYING : The Banks Ram-Air Always dry naturally. After rinsing, Oiled Air Filter comes pre-oiled shake off all excess water and let the and no oiling is necessary for element dry naturally. initial installation. Use Banks 6. AEROSOL OILING Ram-Air Filter Cleaning System (part#90094), available from Gale After cleaning air filter always reoil Banks Engineering to service the before using. Spray Banks Ram-Air Air FIlter. Follow the instructions filter oil down into each pleat with one included with the cleaning sys- pass per pleat. Wait 10 minutes and tem to clean and re-oil your Bank re-oil any white spots still showing. Ram-Air Oiled Air FIlter. 7. OILING HINTS 1. PRE-CLEANING Never use a Banks Ram-Air filter Tap the element to dislodge any large without oil (the filter will not stop the embedded dirt, then gently brush with dirt without the oil). Use only Banks a soft bristle brush. NOTE: If complete Ram-Air filter oil. Banks air-filter oil is cleaning is not practical at this time, a compound of mineral and animal oil reoil the element and reinstall in your blended with special polymers to form vehicle. a very efficient tack barrier. Red dye is added to show just where you have 2. SPRAY-ON CLEANING applied the oil. Eventually the red color Spray Banks air-filter cleaner liberally will fade but the oil will remain and onto the entire element and let soak filter the air. NEVER USE Automatic for 10 minutes. Transmission Fluid. NEVER USE . NEVER USE Diesel Fuel. NEVER USE 3. PAN CLEANING WD40, LPS, or other light-weight oils. Large air-filter elements can be 8. REINSTALL rolled or soaked in a shallow pan of Banks air-filter cleaner. Remove Reinstall your Banks Ram-Air filter immediately and let soak for element with proper care. Make sure approximately 10 minutes. the element seats properly in the filter case. Install the cover making sure it’s : NEVER use gasoline, in the right position. Tighten all the steam, caustic solutions, strong nuts, bolts, screws or clips to factory detergents, high-pressure specifications. nozzles, or cleaning solvents to DO NOT DISCARD clean the filter element. All of 9. these can cause harm to the filter Affix the “Do Not Discard” sticker to media as well as SHRINK and HARDEN the filter case (included with every the rubber end caps. Banks replacement element). Make sure you put the sticker in a highly RINSING 4. visible place to alert your mechanic Rinse off the element with low- not to discard. pressure water. Tap water is okay. PERFORMANCE HINTS Always flush from the clean side to 10. dirty side. This removes the dirt Service every 50-100,000 miles on

14 96496 v.7.0 street-driven applications. Service 3. RINSING more often in offroad or heavy-dust conditions. If an air-filter restriction Rinse the filter element with cool or gauge is installed, then change the warm (not hot) water from the clean element when the air-filter restriction side out in order to flush the dirt out of the filter. It may be necessary to use reaches 18”–H2O. your fingers on the hose to apply light water pressure. Repeat steps 2 and : Extremely fine 3, until the water flowing through the dust from agriculture or offroad media is completely clear of any dirt use will pull the oil from the and debris. element. Frequent reoiling of the element’s clean side might be 5. DRYING required. Completely service when After rinsing, gently shake off exces- practicable. For extra protection sive water and allow to dry naturally. use an air-filter sealing grease Re-install the filter onto the intake sys- on rubber ends of the element. tem, airbox or custom assembly once Service only with Banks air-filter it is dry or just slightly damp. Follow all cleaner and Banks air-filter oil. original installation instructions. 6. REINSTALL DRY FILTER CLEANING Reinstall your Banks Ram-Air filter Clean every 50-100,000 miles on element with proper care. Make sure street-driven applications. Clean the element seats properly in the filter more often in offroad or heavy-dust case. Install the cover making sure it’s conditions. If an air-filter restriction in the right position. Tighten all the gauge is installed, then change the nuts, bolts, screws or clips to factory element when the air-filter restriction specifications. reaches 18”–H2O. 7. DO NOT DISCARD 1. PRE-CLEANING Affix the “Do Not Discard” sticker to the filter case (included with every Carefully tap the air filter element to Banks replacement element). Make dislodge any large embedded dirt or sure you put the sticker in a highly debris. visible place to alert your mechanic not to discard. 2. CLEANING 8. PERFORMANCE HINTS Spray an appropriate DRY AIR-FILTER CLEANER SOLUTION liberally onto both Service every 50-100,000 miles on sides of the entire filter element with street-driven applications. Service the majority applied to the dirty side. more often in offroad or heavy-dust Soak for 10 minutes. Do not allow the conditions. If an air-filter restriction DRY AIR-FILTER CLEANER SOLUTION to gauge is installed, then change the dry on the air filter. element when the air-filter restriction

reaches 18”–H2O. : NEVER use gasoline, -END, SECTION 3- steam, caustic solutions, strong de- tergents, high-pressure nozzles, or cleaning solvents to clean the filter element. All of these can cause harm to the filter media as well as SHRINK and HARDEN the rubber end caps.

96496 v.7.0 15 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