Banks Power

Banks Power
Owner’sManual
with Installation Instructions
Banks Six-Gun
Diesel Tuner
®
For use with Six-Gun switch
2003-06 Ford Power Stroke
6.0L Turbo-Diesel
THIS MANUAL IS FOR USE WITH SYSTEMS 62987 and 62988
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
©2012 Gale Banks Engineering
9/14/12 PN 96450 v.9.0
Products available from Banks Power
for 2003-2007 Ford 6.0L
Banks iQ System
(P/N 61151-61152)
Note: Must upgrade Six-Gun tuner to
63746 to use with Banks iQ.
- 5” touchscreen interface that can
control the Banks Diesel Tuner and/or
SpeedBrake on the fly.
- Interchangable gauge display, read
and clear codes, monitor engine
diagnostics, log data, time your
vehicles runs and much more.
Banks Monster® Exhaust System
Sport (P/N 48790-48793)
Single and Dual (P/N 47285-47292,
47606-47609, 48783-48788)
- Increases exhaust flow, cuts
backpressure, lowers exhaust gas
temperatures (EGTs) and increases
power.
2
96450 v.9.0
Banks Ram-Air Intake System
(P/N 42155)
- Increases your airflow over stock.
- Adds power, improves fuel economy,
lowers EGTs and reduces smoke.
High-Ram Intake
(P/N 42750-42751)
- Increases flow and provides more
uniform air distribution to the
engine for more available power at
a given boost level.
Banks Techni-Cooler® System
(P/N 25974-25975)
- Provides increased air flow to the
engine by increasing air density for
more increased power, lower EGTs
and improved fuel economy.
Banks Brake
(P/N 55467-55468)
- Increases the stopping power of
your truck and extends the service
life of your brakes
Boost and Pyro Gauges
(P/N 64507)
- Keep your engine safe by
monitoring vital engine parameters
Banks Billet Torque Converter
(P/N 72522)
- Higher torque capacity over stock
- Lockup clutch is slip-resistant so
transmission fluids stay cooler and
transmission life is prolonged.
Banks SpeedBrake
iQ Compatible (P/N 55455-55456)
PDA Compatible (P/N 55457-55458)
- Allows for controlled hill decent at
a user defined vehicle speed.
Banks Bullet
(P/N 66524-66525)
- Adds power safely to your vehicle
- Displays critical engine functions
- Engine safeguards
- Change power levels on-the-fly
Banks Diesel Tuner
Six-Gun w/ iQ (P/N 63749)
EconoMind w/ switch (P/N 6374363745)
EconoMind w/ iQ (P/N 63747-63748)
- Adds power safely to your
vehicle
- Engine and transmission
safeguards
- Change power levels on-the-fly
AutoMind Programmer
(P/N 66100)
- Contains Banks tunes that boost
your vehicles HP, Torque and MPG.
- Displays a host of critical engine
functions
- Provides “service technician”
diagnostic capabilities
- Has upgradeable functionality, so it
will never be out of date
Thermocouple
- Add a temperature limiting function
to your Diesel Tuner
Banks Stinger Systems
(P/N 46465-46486)
Contains:
- Ram-Air Intake system
- Monster Exhaust (single or dual)
- EconoMind Tuner w/ Banks iQ
Banks PowerPack Systems
(P/N 46497-46519)
Contains:
- Ram-Air Intake system
- Monster Exhaust (single or dual)
- EconoMind Tuner w/ Banks iQ
- High-Ram
- Techni-Cooler System
Banks Six-Gun Bundle
(P/N 46594-46613)
Contains:
- Ram-Air Intake system
- Monster Exhaust (single or dual)
- Six-Gun Tuner w/ Banks iQ
Banks Big Hoss Bundle
(P/N 46623-46643)
Contains:
- Ram-Air Intake system
- Monster Exhaust (single or dual)
- Six-Gun Tuner w/ Banks iQ
- Big Head Wastegate Actuator
- High-Ram
- Techni-Cooler System
For More Information please call (888) 635-4565
or Visit us online @ www.bankspower.com
96450 v.9.0
3
Disclaimer of Liability & Warranty
THIS IS A HIGH
PERFORMANCE PRODUCT.
USE AT YOUR OWN RISK.
Do not use this product until
you have carefully read the
following agreement.
This sets forth the terms and
conditions for the use of this
product. The installation of
this product indicates that
the BUYER has read and
understands this agreement
and accepts its terms and
conditions.
Disclaimer of Liability
Gale Banks Engineering Inc., and its
distributors, employees, and dealers
(hereafter “SELLER”) shall in no way be
responsible for the product’s proper use
and service. The BUYER hereby waives
all liability claims.
The BUYER acknowledges that he/
she is not relying on the SELLER’s skill
or judgment to select or furnish goods
suitable for any particular purpose
and that there are no liabilities which
extended beyond the description
on the face hereof and the BUYER
hereby waives all remedies or liabilities,
expressed or implied, arising by law
or otherwise, (including without
any obligations of the SELLER with
respect to fitness, merchantability, and
consequential damages) whether or not
occasioned by the SELLER’s negligence.
The BUYER is responsible to fully
understand the capability and limitations
of his/her vehicle according to
manufacturer specifications and agrees
to hold the SELLER harmless from any
damage resulting from the failure to
adhere to such specifications.
4
96450 v.9.0
The SELLER disclaims any warranty
and expressly disclaims any liability
for personal injury or damages. The
BUYER acknowledges and agrees
that the disclaimer of any liability for
personal injury is a material term for this
agreement and the BUYER agrees to
indemnify the SELLER and to hold the
SELLER harmless from any claim related
to the item of the equipment purchased.
Under no circumstances will the SELLER
be liable for any damages or expenses
by reason of the use or sale of any such
equipment.
The BUYER is responsible to obey all
applicable federal, state, and local laws,
statutes, and ordinances when operating
his/her vehicle, and the BUYER agrees
to hold SELLER harmless from any
violation thereof.
The SELLER assumes no liability
regarding the improper installation
or misapplication of its products. It is
the installer’s responsibility to check
for proper installation and if in doubt,
contact the manufacturer.
The BUYER is solely responsible for all
warranty issues from the automotive
manufacturer.
Limitation of Warranty
Gale Banks Engineering Inc. (hereafter
“SELLER”), gives Limited Warranty as
to description, quality, merchantability,
fitness for any particular purpose,
productiveness, or any other matter of
SELLER’s product sold herewith. The
SELLER shall be in no way responsible
for the product’s open use and service
and the BUYER hereby waives all rights
except those expressly written herein.
This Warranty shall not be extended
or varied except by written instrument
signed by SELLER and BUYER.
Please see enclosed warranty
information card, or go to www.bankspower.com/warranty,
for warranty information regarding
your product. All products that are in
question of Warranty must be returned
shipping prepaid to the SELLER and
must be accompanied by a dated proof
of purchase receipt. All Warranty claims
are subject to approval by Gale Banks
Engineering Inc.
Table of Contents
Under no circumstance shall the SELLER
be liable for any labor charged or travel
time incurred in diagnosis for defects,
removal, or reinstallation of this product,
or any other contingent expense.
Section 2........................................... 15
Installation of the Six-Gun Selector
Switch
Under no circumstances will the SELLER
be liable for any damage or expenses
incurred by reason of the use or sale of
any such equipment.
Disclaimer of Liability ...................... 4
& Warranty
General Installation Practices........ 6
Section 1............................................. 8
Installation of Wiring Harness,
Connections and Six-Gun Module
Section 3........................................... 22
Thermocouple Installation Instructions
for Optional Gauge Package Installation
Section 4........................................... 24
Automatic Transmission Learning
In the event that the
buyer does not agree
with this agreement:
Section 5........................................... 25
Troubleshooting
The buyer may promptly return
this product, in a new and
unused condition, with a dated
proof-of-purchase, to the placeof-purchase within thirty (30)
days from date-of-purchase for a
full refund, less shipping and/or
restocking fee.
Section 7........................................... 28
Removal of the Six-Gun Diesel Tuner
Section 6........................................... 27
Placement of the Banks Decals
The installation of this product
indicates that the buyer has
read and understands this
agreement and accepts its terms
and conditions.
96450 v.9.0
5
General Installation Practices
Dear Customer,
If you have any questions
concerning the installation
of your Banks Six-Gun Diesel
Tuner, please call our Technical
Service Hotline at (888) 8392700 between 7:00am and
5:00pm (PST). If you have any
questions relating to shipping
or billing, please contact our
Customer Service Department
at (888) 839-5600.
Attention!
Before proceeding with these
instructions, please carefully read
the DISCLAIMER OF LIABILITY
and LIMITATION OF WARRANTY
statement located on page 4 of
this manual.
Thank you.
The Banks Six-Gun Diesel Tuner
has six power levels adjustable by
the supplied Six-Gun switch. Level
1 is stock. Each additional higher
level adds approximately 20% of the
available power increase. To prevent
damage to the factory transmission,
Banks recommends that both
automatic and manual transmission
vehicles do not exceed Level 4 while
the vehicle is experiencing load
(towing, climbing a steep grade,
carrying a load, etc.).
To use the higher levels of the Six-Gun
Diesel Tuner while towing or climbing,
airflow improvements must be made
to lower the exhaust gas temperature
(EGT) entering the turbo. The EGT
should not exceed 1400º F for more
than a few seconds. Elevated EGT
can damage the turbocharger and the
engine.
6
96450 v.9.0
Tools Required:
Six-Gun module
• Inch and metric sockets
• Inch and metric combination and
open-end wrenches
• Pliers
• Ford stereo removal tool
(’03-04 model year vehicles only)
• Wire cutters
• Scissors
• Drill motor
• 1⁄ 8” drill bit
• 13⁄ 32” drill bit
Additional tools required for
Thermocouple installation
• 7⁄ 16” drill bit
• Tap handle
• 1⁄ 4” NPT tap
Highly recommended tools and
supplies for Thermocouple:
• Foot-pound torque wrenches
• Penetrating oil or light lubricant
spray
• Anti-seize compound
• Heat gun
1. Before starting work, familiarize
yourself with the installation procedure
by reading all of the instructions.
2. The exploded views provide 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 side, and the right side to the
passenger side.
4. Disconnect the negative (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. When raising the front
of the vehicle, put the transmission in
park (automatic) or reverse (manual),
set the parking brake, and block the
rear wheels. When raising the back
of the vehicle, be sure the vehicle is
on level ground and the front wheels
are blocked securely. 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 engine
damage upon start-up.
8. Save this Owner’s Manual as a
reference for system maintenance and
service.
9. Banks recommends that a
Pyrometer (EGT) gauge and Boost
gauge be installed with the SixGun Diesel Tuner to help monitor
performance and exhaust gas
temperature of the vehicle (see part
numbers on pages 2-3). To further
increase engine life by lower EGT’s,
Banks also recommends installing a
Monster Exhaust® system (see pages
2-3).
96450 v.9.0
7
Section 1:
Installation of wiring harness, connections and six-gun
module
1. Disconnect the battery ground
cables from each of the batteries.
Secure the cables so that they do not
come in contact with the battery posts
during the installation.
2. Remove the (+) battery cable from
the driver side battery.
3.
Remove the driver side plastic
battery cover, as shown in Figure 1.
This is accomplished by depressing a
tab at the front and rear of the cover.
Be careful not to damage the
cover, as it will be re-installed.
4. Remove the driver side battery hold
down clamp (8mm socket). Remove
the driver 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
Figure 1
8
on opposite corners. Failure to
follow these instructions may
result in personal injury.
5. Locate the Powertrain Control
Module (PCM) on the driver side of the
vehicle engine compartment
(see Figure 2).
6. Disconnect the middle connector
from the PCM by opening the overcenter retaining clamp as shown in
Figure 2.
2003-04 model year vehicles: Route
the middle connector under the power
steering fluid reservoir.
2005-06 model year vehicles: Route
the middle connector in the most
direct path to the area near the fuse/
relay box.
Plug the connector into the connector
on the Six-Gun module labeled,
“VEHICLE HARNESS”.
Removal of the battery box cover
96450 v.9.0
Figure 2
View of the PCM after the battery cover has been removed
7. Plug the supplied wiring harness
“A” (as shown in Figure 5) into the
Six-Gun module connector labeled,
“BANKS HARNESS.”
c.) Automatic Transmission Vehicles Only: Brown/orange wire on
connector “B”, pin #14
(see Figure 4)
2003-04 model year vehicles: Route
the harness under the power steering
fluid reservoir.
Note: Apply a liberal amount of the
supplied dielectric grease to the T-tap
prior to installation.
2005-06 model year vehicles: Route
the harness to the PCM in the most
direct path possible.
mating connector on the Six-Gun
module as shown in Figure 5.
Plug the harness connector into the
middle PCM connector (Connector C).
8. Remove the plastic covers on PCM
connectors “A” and “B” as shown in
Figure 2.
9.
T-tap the following wires (see
Figure 2 for the location of each
connector):
a.) Red wire on connector “A”,
pin #34 (see Figure 3)
b.) dark blue/light green wire on
connector “A”, pin #38
(see Figure 3)
10. Plug wiring harness “B” into its
11. Route the VIOLET and GRAY wires
from the Six-Gun module and the
FUSED power wire from harness “B” to
the PCM.
2003-04 model year vehicles: Route
the wires under the power steering
fluid reservoir.
2005-06 model year vehicles: Route
the wires in the most direct path to
the PCM.
12.
Connect the fused power
wire from the Six-Gun module to
the red wire that was T-tapped on
connector “A”.
96450 v.9.0
9
Figure 3
Location of pin #34 and #38 on Connector A
Figure 4
Location of pin #14 on Connector B
10
96450 v.9.0
13.
Connect the violet wire from
the Six-Gun module to the dark blue/
light green wire that was T-tapped
on connector “A”.
14. Automatic Transmission Vehicles
Only: Connect the gray wire from
the Six-Gun module to the brown/
orange wire that was T-tapped on
connector “B”.
15. Manual Transmission Vehicles
Only: The gray wire will not be used.
Unplug the manifold absolute pressure
sensor (MAP) connector shown in
Figure 6. The MAP connector can be
unplugged by sliding the red safety
slide down, pressing the locking
button, then pulling on the connector.
16. Plug the Six-Gun MAP connector
into the MAP sensor. Plug the factory
MAP connector into the Six-Gun MAP
wiring harness. Route the harness
Figure 5
from the Six-Gun to the MAP sensor as
shown in Figure 7. Use the supplied
zip ties to secure the MAP harness
to the factory harness. Failure to
follow the recommended wire
routing may result in a melted
wire.
17. Route the Six-Gun Selector
switch/instrument wire harness
through the firewall to the passenger
compartment. When passing through
the firewall, either make a hole in a
factory grommet or drill a hole and use
a new grommet. If drilling, check the
backside to make sure there are no
components that may be damaged by
drilling.
18. 2003-04 model year vehicles
only: Remove the clip shown in
Figure 8 to create adequate room
to mount the Six-Gun module to the
driver side inner fender.
Six-Gun and supplied wiring harness
96450 v.9.0
11
Figure 6
MAP sensor location
Figure 7
MAP sensor wire routing
12
96450 v.9.0
19.
2003-04 model year vehicles
only: The module shown in Figure
9 will appear only in four-wheeldrive vehicles. This may need to be
relocated as shown in Figure 9 to
make room for the Six-Gun module.
The mounting location of this module
by the factory has not been consistent
on early vehicles.
Figure 8
20.
2003-04 model year vehicles:
The Six-Gun module will be mounted
to the inner driver side fender, behind
the power steering fluid reservoir.
2005-06 model year vehicles: The
Six-Gun module will be mounted on
top of the fuse and relay box near the
inner drivers side fender.
Removal of hood latch cable clip (2003-04 model year vehicles only)
Figure 9
Electronics module to relocate on 4-wheel-drive vehicles
(2003-04 model year vehicles only)
96450 v.9.0
13
Figure 10
Six-Gun module installed on the inner fender (2003-04
model year vehicles only)
Figure 10a
Six-Gun module installed on the fuse box on 2005-06 modelyear vehicles
Make sure the entire mounting surface
is clean and free of dirt and oil before
mounting the Six-Gun Diesel Tuner.
Clean and dry as required using a cloth
damped in rubbing alcohol or similar
cleaning solution.
21.
Remove the adhesive backing
from the (2) dual-lock fasteners on the
back of the Six-Gun module and affix
the module to:
14
96450 v.9.0
2003-04 model year vehicles: The
inner driver side fender as shown in
Figure 10.
2005-06 model year vehicles: The
top of the fuse box cover as shown in
Figure 10a.
-end, section 1-
Section 2:
Installation of the six-gun selector switch
Caution: Do not use excessive
force when working on plastic
parts. Permanent damage to the
part might result
electrical connections on the back of
the dash once it has been detached.
For 2003-04 model year vehicles,
follow the selector switch
installation procedure below. For
2005-06 model year vehicles, skip
to step 28.
27.
26. Remove the dash from the
vehicle.
22. Remove the lower driver side
Cut out the template in
Figure 12 and tape to the backside of
the dash panel as shown in Figure 13.
The template will be used as a guide
for drilling the holes to locate the SixGun selector switch.
23. Remove the stereo using Ford
For 2003-04 model year vehicles,
skip to step 30 to finish the selector
switch installation procedure.
interior panel that allows access to the
fuse box.
stereo removal tools as shown in
Figure 11. These are readily available
at automotive supply stores.
24. Remove two (2) bolts that reside
above the stereo. These are accessible
once the stereo has been removed.
25. Detach the dash. At this point
28.
2005-06 Automatic
Transmission vehicles: Set the
vehicle’s parking brake. Insert the
key and turn the vehicle on without
starting it. Pull the shift lever down
into first gear to allow clearance for
dash panel removal.
the dash is held in place entirely by
removable fasteners. Disconnect all
Figure 11
Removal of the stereo (2003-04 model year vehicles only)
96450 v.9.0
15
All 2005-06 vehicles: Pull the plastic
trim surrounding the instrument panel
and radio / climate controls towards
you until it releases from the main
dashboard — it is attached by a series
of spring clips around its perimeter.
Disconnect all electrical connectors
from the back of the dash trim and
remove it from the vehicle.
29.
Cut out the template in
Figure 12a and tape it to the front of
the dash panel as show in Figure 13a.
The template will be used as a guide
for drilling holes to locate the Six-Gun
selector switch.
30. All model years: Using a 13⁄ 32”
Uni-drill, center the bit onto the 13⁄ 32”
drill location on the template and
slowly drill through. Using a 1⁄ 8” drill
bit, center and drill through the 1⁄ 8”
location on the template. Remove and
discard the template and any plastic
shavings. De-burr the drilled holes as
needed to ensure that the Six-Gun
selector switch fits squarely against
the dash panel.
31. Remove the nut and internal
tooth washer from the Six-Gun switch
and test fit the switch into the drilled
holes. Ensure that the alignment pin
properly fits in the 1⁄ 8” hole. Enlarge
the holes as necessary to allow the
switch to properly fit. Do not fasten
the switch to the dash panel yet.
32.
Align the Banks Six-Gun label
on the previously drilled hole on the
front of the dash panel. Make sure the
entire mounting surface is clean and
free of dirt and oil before mounting the
label. Clean and dry as required using
a cloth damped with rubbing alcohol
of similar cleaning solution. Remove
the adhesive backing and affix the
label to the dash panel. Hold the label
against the panel for approximately
20 seconds while applying pressure to
allow the adhesive to properly adhere
to the surface.
16
96450 v.9.0
33. Rotate the switch counter-
clockwise until the shaft stops. Verify
that the washer tab is inserted into the
#6 position on the switch as shown in
Figure 14.
Note: All of the power settings may
not be usable if the tab is not in
slot #6.
34. Install the switch through the
13⁄ 32”
hole on the backside of the
bezel. The alignment pin should rest
in the 1⁄ 8” hole and the switch fully
rotated counterclockwise. Secure the
switch with the internal tooth washer
and nut. Snug the nut. Be careful not
to over-torque the nut and damage the
threads.
35. Install the knob on the shaft
facing the #1 Level on the Six-Gun
label. On the knob, snug the two (2)
set screws with the supplied 0.050”
hex key wrench. The completed switch
installation will appear as shown in
Figure 15.
36. Re-install the dash panel, make
all electrical connections that were
disconnected, and re-install the radio
(2003-04 model year vehicles only).
37. Route the Six-Gun switch’s cable
to the wire harness that was routed
into the passenger compartment from
the Six-Gun module, and plug the 2-pin
connector into the corresponding
connector on the Six-Gun harness.
Note: The 6-pin plug on the wire
harness routed from the Six-Gun
module to the passenger compartment
will not be used.
38.
Reinstall the lower interior panel
that allows access to the fuse box
(2003-04 vehicles only), the battery
cover and battery cables.
Figure 12
Templates for locating
the Six-Gun switch on the dash
panel.
2003-04
model year
vehicles only
Align Edge with Top
of the Dash Panel
1/8" Drill
Location
2005-06 model
year vehicles only
13/32" Drill
Location
2005Ford
Ford 6.0L
6.0L ONLY
ONLY
2005-06
Align Edge with Bottom
of the Dash Panel
96450 v.9.0
17
This page left blank intentionally
18
96450 v.9.0
Figure 13
Template taped to back of dash on 2003-04 model year vehicle,
ready to be drilled.
2003-04 model year vehicles only
Figure 13a
Template taped to front of dash on 2005-06 model year
vehicle, ready to be drilled.
2005-06 model year vehicles only
96450 v.9.0
19
Figure 14
Six-Gun switch, orientation of the tab on the washer
-end, section 2-
20
96450 v.9.0
Figure 15
Finished installation of the Six-Gun switch on 2003-04 model
year vehicles
Figure 15a Finished installation of the Six-Gun switch on 2005-06 model
year vehicle
96450 v.9.0
21
Section 3:
Thermocouple Installation Instructions for Optional
Gauge Package Installation
1. The thermocouple monitors
the temperature of the exhaust
gases entering the turbocharger
at the turbine housing. Installation
requires that the exhaust manifold
be drilled near the manifold outlet.
It is recommended that the manifold
be removed from the engine to
thoroughly clean out all metal chips
from drilling. All metal shavings must
be cleaned from the manifold to avoid
turbine wheel damage and possible
interference with the turbochargers
variable geometry turbine stage.
5. Tap the hole for a 1⁄ 4” NPT thread.
Check the thread depth as you tap
by periodically removing the tap and
screwing the pipe coupling into the
tapped hole. The coupling should
thread in 3 to 31⁄ 2 turns hand tight.
Do not install the probe in place at
this time. Caution: Running the tap
too deeply can prevent the pipe fitting
from properly sealing.
2.
7.
Disconnect the Exhaust Back
Pressure Sensor tap located at the
front of the driver side manifold. The
pressure tap must be removed by
using a 9⁄ 16” open-end wrench to hold
the fitting stationary, and loosen the
tube using a 5⁄ 8” open-end wrench. The
fitting is shown in Figure 16.
Note: Failure to hold the fitting
stationary will damage the tube upon
removal.
3.
Remove the driver side exhaust
manifold.
4. Drill a 7⁄ 16” hole in the driver side
exhaust manifold at the location
shown in Figure 17.
Figure 16
22
6. Remove the NPT fitting from the
pyrometer and install it on the exhaust
manifold. Use anti-seize lubricant on
the threads and torque to 14–16 lb-ft.
Remove all metal chips from the
exhaust manifold.
Note: Failure to remove all metal chips
could result in catastrophic damage
to the turbocharger’s turbine wheel
or interfere with the operation of the
variable geometry vane mechanism.
8. Re-install the exhaust manifold.
Apply anti-seize lubricant to the
manifold bolt threads and torque to
28 lb-ft. Use the tightening sequence
shown in Figure 18.
9. Tighten the turbocharger adapter
pipe fasteners to 20 lb-ft as shown in
Figure 19.
Location of the static exhaust pressure line tap
96450 v.9.0
Figure 17
Location to drill and tap the driver side exhaust manifold for
the DynaFact pyrometer sensor
Figure 18
Exhaust manifold
tightening sequence
10.
Reconnect the exhaust
backpressure static line tube.
11. Connect the sensor wire to the SixGun module with the supplied screws.
The yellow sensor wire attaches to the
free yellow wire on the Six-Gun module.
The red sensor wire attaches to the free
red wire on the Six-Gun module.
Figure 19
Turbocharger
adapter pipe torque specification
12. Slide the heat shrink over the
exposed metal junction, and supply
moderate heat to seal the connection.
A heat gun works well.
13. Route the pyrometer to the exhaust
manifold and install the DynaFact
pyrometer probe in the fitting.
-end, section 3-
96450 v.9.0
23
Section 4:
automatic transmission learning
The 6.0L Ford Trucks equipped with
the TorqShiftTM 5-speed automatic
overdrive transmission use an adaptive
shift control logic. This will require the
transmission to learn how to cope with
the additional power created by the
Banks Power products before it will
shift properly. Additionally, the Banks
Six-Gun Diesel Tuner will require a
short learning curve to characterize the
transmission in order to optimize fueling
during gear change events. The following
sequence must be followed to allow
for collaborative learning between the
Banks Six-Gun and the transmission’s
control system. Failure to follow the
sequence can result in damage to the
transmission.
Perform the following sequence
at a location where it is safe to
accelerate to 60 mph without
exceeding the posted speed limit.
1. Start the truck and allow the engine
to reach normal operating temperature.
2. Turn the Six-Gun selector switch to
the #2 position.
3. Accelerate with the pedal to the floor,
from a standing start to 60 mph. Repeat
three (3) times.
4. Cruise at 30 mph, then press the
accelerator to the floor to cause the
transmission to downshift. Continue
accelerating to 60 mph.
5. Repeat steps 3 and 4 for the next
power setting.
6. Continue to increase the power
setting and drive cycle until the desired
power setting is achieved.
24
96450 v.9.0
The TorqShift™ 5-speed automatic
transmission will continually adapt
to the power output of the engine
to optimize shift quality. This will
result in the transmission un-learning
how to cope with the higher power
settings of the Six-Gun Diesel Tuner,
if the selector switch is returned to
a lower power setting. The rate that
the transmission un-learns how to
cope with the higher power levels,
when switching to a lower power
level, depends on the driving cycle.
The transmission will quickly adapt
to the power setting if the driving
cycle includes regular gear changes
at high loads. The transmission
learning procedure will need to be
repeated when switching back to
the higher power settings once the
transmission adapts to the lower
power settings. It will be apparent
when the transmission adapts to the
lower settings by monitoring the feel
of the gearshift. Gear changes will
be noticeably harder when initially
switching from a higher to lower
power setting. This will soften as
the transmission adapts to the new
setting.
For example: If the transmission has
adapted to level 3 and it is desired to
go to level 6, the transmission learning
procedure can start at level 3.
IF TRANSMISSION SLIP IS DETECTED
DURING THE TRANSMISSION LEARN
PROCESS, REDUCE THE POWER LEVEL
BY ONE, AND START OVER AT STEP 3.
-end, section 4-
Section 5:
troubleshooting
If you feel that your Six-Gun Diesel
Tuner is not functioning properly,
some diagnostics can be performed.
Your Six-Gun Diesel Tuner is equipped
with diagnostic features that will
detect and display certain errors.
Remove the Six-Gun Diesel Tuner from
its mounting location while keeping
all connectors plugged in. Turn
the vehicle key to the ON position.
Observe the two LEDs mounted on
the upper corner of the Six-Gun Diesel
Tuner.
• A steady GREEN LED will
illuminate if all wire connections are
correct, the engine is running and the
engine coolant temperature is within
its normal operating range (100 to
220°F).
• The GREEN LED will flash if all wire
connections are correct, the engine
is running, but the engine coolant
temperature is not within its normal
operating range. The GREEN LED will
stop flashing once the engine coolant
temperature is with normal operating
range. Power will not be added if the
coolant temperature is not within its
normal range (not to be confused with
Speed-Loader flash on power up).
• None of the LEDs will illuminate if
the fuse on the Six-Gun wiring harness
is blown or the power supply hook-up
is not properly connected with the
engine running. The power supply
wire is the fused wire that connects
to the t-tap at the PCM. If the power
connection and fuses are okay,
contact Banks Technical Service.
• The RED LED will flash if a
connection is incorrect or if there is
a problem with the system, when
the engine is running. The RED LED
will flash in sequence to identify a
diagnostic code. A Six-Gun Diesel
Tuner’s diagnostic code is comprised
of 2 digits. Each code is expressed in a
sequence of 2 sets of the flashing RED
LED separated by a brief flashing of
the GREEN LED. Each set of a number
of RED LED flashes represents a digit.
A longer flashing of the GREEN LED
separates the sequences. The LEDs
will continue to flash to display all the
errors, and then repeat. Table 1 lists
some common diagnostic codes.
For example, if a faulty thermocouple
is detected (code 2,3) by the SixGun Diesel Tuner, the following red
and green LED flashing sequence is
observed when the key is ON:
(1.) Two times flashing RED LED
(2.) One time quick flashing
Green LED
(3.) Three times flashing RED LED
(4.) One time longer flashing
GREEN LED
The above flashing sequence will
repeat continuously. When the
problem is corrected, the diagnostic
code will be eliminated and replaced
with a steady green light.
Note: If multiple codes are set, they
will be displayed in a series separated
by the longer flashing green LED.
When reading codes, make sure to
watch the entire series until you see
the first code repeat.
-end, section 5-
96450 v.9.0
25
Table 1: Banks Six-Gun Diagnostic Codes
Diagnostic
Code Description
Course of Action
1,1
Faulty Injection
Control Pressure (ICP)
input signal
Check 46-pin connectors. Reset Six-Gun
Diesel Tuner by turning key on and off.
1,2
Faulty Manifold
Absolute Pressure
(MAP) input signal
1,3
Faulty Six-Gun signal
input
Code
1,4
Check barometric­T-tap connection
(VIOLET wire). Boost pressure displayed
by the gauges will not be accurate when
changing altitude, but the module will
operate normally.
2,3
Faulty Injection Control Check the 46-pin Six-Gun Diesel Tuner
Pressure (ICP) output
connectors. Reset Six-Gun Diesel Tuner
signal
by turning key on and off.
Check MAP sensor connection and 12-pin
Faulty Manifold
Six-Gun Diesel Tuner connector. Reset
Absolute Pressure
Six-Gun Tuner by turning key on and
(MAP) output signal
off.
Faulty thermocouple
Check thermocouple ring terminal
signal
connections.
2,4
TCC stuck (automatic
transmission ONLY)
Check TCC T-tap connection (GRAY wire).
Monitor code occurrence. Contact Banks
Technical Service if occurrence becomes
frequent.
3,4
Faulty CAN bus signal
Check 46-pin connectors. Reset Six-Gun
Diesel Tuner by turning key on and off.
2,1
2,2
26
Faulty barometric
pressure sensor
Check MAP sensor connection and 12-pin
Six-Gun Diesel Tuner connector. Reset
Six-Gun Tuner by turning key on and
off.
Make sure the Six-Gun switch is
connected to the main wire harness.
Reset the Six-Gun Diesel Tuner by turning
the key on and off.
96450 v.9.0
Section 6:
placement of the banks power decals
Figure 20
Placement of the Banks decals
1.
Dimensions are given in
Figure 20 to position the Banks
decals to provide a clean factory
appearance.
-end, section 6-
96450 v.9.0
27
Section 7:
removal of the six-gun diesel tuner
1.
If the Six-Gun Diesel Tuner should
ever need to be removed from the
vehicle, perform the following:
1.) Disconnect the Six-Gun’s 46-pin
connector (connector C) from the
middle connection on the PCM.
2.) Re-connect the vehicle’s 46-pin
connector back into the middle
connection on the PCM.
3.) Disconnect the Gray and Violet
wires from the T-taps on the PCM’s
“A” and “B” connectors (the SixGun’s fused power wire does not
need to be removed).
4.) Disconnect the Six-Gun’s MAP
connections from the vehicles MAP
sensor and harness. Re-connect the
vehicle’s MAP connector back into
the MAP sensor.
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
5.) Disconnect the 2-ring terminals
from the EGT probe.
6.) Disconnect the Six-Gun’s 12-pin
harness connector (harness “B”
shown in Figure 5).
7.) Remove the Six-Gun module.
Failure to follow the above instructions
when removing the module will result
in a “Check Engine” light on the dash
and a Diagnostic Trouble Code being
stored in the factory computer, in
addition to the engine not running.
-end, section 7-
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