Installation Instructions

Installation Instructions
Owner’sManual
with Installation Instructions
Banks Ram-Air®
Intake System
2004-2008 Ford 5.4L
F150 Trucks
THIS MANUAL IS FOR USE WITH KIT 41806
Gale Banks Engineering
546 Duggan Avenue • Azusa, ca 91702
(626) 969-9600 • Fax (626) 334-1743
Product Information & Sales: (888) 635-4565
bankspower.com
©2010 Gale Banks Engineering
06/24/10 PN 96881 v.5.0
General Installation Practices
Dear Customer,
If you have any questions
concerning the installation of
your Banks Ram-Air 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
1. For ease of installation of your
Banks Ram-air intake system,
familiarize yourself with the procedure
by reading the entire manual before
starting work. This manual contains
16 pages of copy, illustrations and
parts listing. If any pages are missing
from this manual please call Gale
Banks Engineering immediately for a
replacement.
2. The exploded view of the Ram-Air
assembly (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 before beginning work. If
there are two batteries, disconnect
both.
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96881 v.5.0
5. 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.
6. During installation, keep the
work area clean. If foreign debris
is transferred to any Banks system
component, clean it thoroughly before
installing.
7. 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 parking 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.
Notification
The Banks Ram-Air Filter
comes pre-oiled and no oiling
is necessary for the initial
installation. Service the filter
as specified in the Filter
Maintenance Section of this
manual.
Tools Required:
• 3⁄ 8” drive ratchets with metric and
standard sockets
• Standard and Phillips head
screwdrivers
• Standard and needle-nose pliers
• Clean shop towels or rags
Table of Contents
Section 1 . . . . . . . . . . . . . . . . . . . . . . 4
General Assembly
Section 2 . . . . . . . . . . . . . . . . . . . . . . 6
Ram-Air Installation
Section 3 . . . . . . . . . . . . . . . . . . . . . 16
Filter Maintance
• 5⁄ 16 nut driver
96881 v.5.0
3
Section 1
General Assembly
Figure 1
Item # Part #
1
41807
2
41808
3
42158
4
41810
5
41811
6
41812
7
94300
8
92904
9
92872
10
93067
11
93047
12
91226
13
91128
14
91736
15
91718
16
*
17
*
18
*
19
96009
Description
HOUSING, RAM-AIR FILTER
COVER, RAM-AIR HOUSING
AIR FILTER ELEMENT, RAM-AIR
HIGH-RAM, RAM-AIR
BRACKET, LEFT
BRACKET, RIGHT
BELLOWS, 4.5”
HOSE CLAMP, #104
HOSE CLAMP, #72
GASKET, MAF SENSOR
GROMMET, HOUSING FOOT
SCREW, TRUSS HEAD, PHILLIPS, 5⁄16-18 X 3⁄4
SCREW, TRUSS HEAD, PHILLIPS, 1⁄4-20 X 3⁄8
SCREW, HEX FLANGE HEAD, M6 X 1.0 x 10mm
SCREW, TRUSS HEAD, PHILLIPS, 6-32 X 3⁄8
GROMMET, INLET (STOCK)
GROMMET, THROTTLE BODY (STOCK)
MAF SENSOR (STOCK)
BANKS UROCAL
QTY
1
1
1
1
1
1
1
1
2
1
2
4
4
4
2
*
*
*
2
* These are stock components that will be reused with the Banks Ram-Air System.
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96881 v.5.0
96881 v.5.0
5
Section 2
Ram-Air Installation
Use the Bill of Materials Chart and
the General Assembly Drawing to
reference component nomenclature
and location. Use caution when
working in the engine compartment.
Make sure the engine has been OFF
for several hours and cool.
You are about to install the Banks
Ram-Air Intake System. Read and
follow all steps before working on the
vehicle. Some components from the
stock air intake system will remain
in service. Take care when removing
stock air intake components to not
damage them.
1. Disconnect the Mass Airflow sensor
(MAF) located on the air filter housing
and set the connector aside.
2. Remove the PCV vent hose
connection located on the air housing
assembly and set the connector aside.
3. Remove the bolt located near the
power steering reservoir that fastens
the intake tube to the power steering
bracket. See Figure 3.
Figure 2
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96881 v.5.0
4. Pull out the intake snorkel and
grommet from the inner fender.
5. Remove and set aside the four M6
bolts that secure the air filter housing to
the engine bay. Note: The M6 bolts will
not be reused. See Figure 4.
6. Remove the air filter housing along
with the attached intake tube from the
engine compartment and set aside.
See Figure 5.
7. Using the supplied torx tool bit,
remove the MAF sensor and the stock
MAF sensor gasket from the air filter
housing and set aside. Note: Take care
when handling the MAF sensor. See
Figure 6.
8. Locate the supplied MAF sensor
gasket from your Banks kit and install
the gasket on the MAF sensor. Note:
Make sure to remove the stock gasket
from the MAF sensor before installing
the Banks gasket. Make sure the
supplied MAF sensor gasket is aligned
as shown in Figure 7.
Figure 3
Figure 4
96881 v.5.0
7
Figure 5
Figure 6
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96881 v.5.0
9. Using the supplied screws, lightly
tighten the MAF sensor to the Banks
High-Ram intake tube.
10. Remove the stock throttle body
gasket from stock air filter housing.
See Figure 8.
11. Insert throttle body gasket onto
the Banks High Ram. Make sure the
throttle body gasket is installed flush
past the beaded lip.
12. Install the supplied brackets using
the supplied phillips head screws
(1⁄ 4-20) screws to the Banks High Ram.
Install the ‘wide’ bracket on the side
with the aluminum hose connection as
shown. See Figure 9.
13. Install the Banks High Ram onto
throttle body. Make sure to fit all the
way flush to bottom of the throttle
body lip.
14. With the two supplied brackets
fastened to the Banks Ram Air Intake,
align the brackets to the intake
manifold. Fasten the brackets to
the engine manifold using the four
supplied M6 flange head bolts. Note:
These are the only metric bolts in the
kit. See Figure 10.
15. Remove the stock air intake hose
‘L’ bracket attached to the power
steering reservoir bracket. See Figure
11.
16. Reinstall the stock nut to refasten
the stock power steering reservoir
bracket. Note: Only one nut will be
used to refasten the stock power
steering bracket.
17. Connect the MAF connector to
MAF sensor.
18. Connect the factory PCV vent
hose to the PCV connection on the
Banks Ram Air Intake.
19. Locate the supplied filter hose
clamp and install on filter.
Figure 7
96881 v.5.0
9
Figure 8
Figure 9
10
96881 v.5.0
Figure 10
Figure 11
96881 v.5.0
11
Figure 12
20. Locate the Banks filter cover.
clamps onto each end of the bellows.
Install one end of the bellows onto the
Banks housing then tighten the hose
clamp.
21. Insert Banks filter cover onto the
25. Install Banks housing into vehicle
Install the Banks filter onto the Banks
filter cover. Tighten Banks filter hose
clamp. See Figure 12.
Banks air housing. Locate supplied
5⁄ 16-18 screws and fasten the cover
to the housing. Note: make sure the
Banks cover is lined up correctly. See
Figure 13.
22. Locate the previously removed
stock intake snorkel gasket and install
it onto the Banks housing as shown.
See Figure 14.
23. Locate the grommets supplied in
your kit and install as shown in Figure
15. Install the grommet end into the
larger hole then slide into smaller hole.
Do both grommets.
24. Locate the supplied bellows and
bellows hose clamps. Fit both hose
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96881 v.5.0
compartment. Insert snorkel into stock
air intake opening then slide Banks
housing feet into previously installed
rubber grommets. See Figure 16.
26. Fit the Banks bellows into the
Banks High Ram Intake. Tighten the
hose clamp.
27. Re-connect battery grounds.
28. You have successfully completed
the installation of the Banks Ram-Air
Intake system. See Figure 17. Make
sure to go over all hose clamps for
tightness and connectors for a sure fit.
Make sure that the intake tube is not
touching any engine components.
-end, section 2-
Figure 13
Figure 14
96881 v.5.0
13
Figure 15
Figure 16
14
96881 v.5.0
Figure 17
96881 v.5.0
15
Section 3
Filter Maintance
Notification
The Banks Ram-Air Filter
comes pre-oiled and no oiling
is necessary for the initial
installation. Service the filter as
specified in this Section of the
manual.
1. Service Banks Ram Air Filter every
50-100,000 miles on street-driven
applications. Service more often in offroad or heavy-dust conditions.
2. Use Banks Ram Air Filter cleaning
system (part # 90094), available from
Gale Banks Engineering to service
the Air Filter. Follow the instructions
included with the cleaning system
to clean and re-oil your Banks Ram
Air Filter. No gasoline cleaning, No
steam cleaning, No caustic cleaning
solutions, No strong detergents, No
high pressure car wash, No parts
cleaning solvents. Any of these No’s
can cause harm to the cotton filter
media plus SHRINK and HARDEN the
rubber end caps.
CAUTION! Extremely fine dust from
agriculture or off-road use will pull
the oil from the element. Frequent
re-oiling of the element’s clean
side might be required. Completely
service when practicable. For extra
protection use an air-filter sealing
grease on rubber ends of the
element. Service only with Banks
Ram-Air-filter cleaner and Banks
Ram-Air-filter oil.
-end, section 3-
Gale Banks Engineering
546 Duggan Avenue • Azusa, CA 91702
(626) 969-9600 • Fax (626) 334-1743
Product Information & Sales: (888) 635-4565
www.bankspower.com
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