Banks Big Hoss Engine Module

Banks Big Hoss Engine Module
Owner’sManual
with Installation Instructions
Banks Big Hoss
Engine Module
1994-2003 Ford Power Stroke 7.3L Turbo-Diesel
THIS MANUAL IS FOR USE WITH P/N 66505
Gale Banks Engineering
546 Duggan Avenue • Azusa, ca 91702
(626) 969-9600 • Fax (626) 334-1743
Product Information & Sales: (800) 438-7693
bankspower.com
©2010 Gale Banks Engineering
08/20/10 PN 96757 v.2.0
Also Available from Banks Power
for ‘94-03 Ford 7.3L
‘94-03 Ford 7.3L
Banks Power Elbow
99-03 (P/N 48651-48652, 4866148663)
- Reduces stock outlet and pipe
backpressure
Banks Brake
99-03 (P/N 55202-55207)
- Increases the stopping power of
your truck and extends the
service life of your brakes
Banks Monster® Exhaust System
94-97 Single (P/N 46296-46299)
99-03 Sport (P/N 48789)
99-03 Single and Dual (P/N 4865348660,
47391-47399)
- Increases exhaust flow, cuts
backpressure, lowers exhaust gas
temperatures (EGTs) and increases
power.
Banks SmartLock
99-03 (P/N 55266)
- Reduces wear on transmission
- Locks Torque Converter and raises
tran s-line pressure
- Works with Banks Exhaust Brake
Banks Ram-Air Intake System
99-03 (P/N 96885)
- Increases your airflow over stock.
- Adds power, improves fuel
economy, lowers EGTs and reduces
smoke.
Banks Techni-Cooler® System
94-97 (P/N 25970)
99-03 (P/N 25971-25973)
- Provides increased air flow to the
engine by increasing air density for
more increased power, lower EGTs
and improved fuel economy.
2|
9 6 7 5 7 v. 2 . 0
Banks Billet Torque Converter
94-03 (P/N 72521)
- Higher torque capacity over stock
- Lockup clutch is slip-resistant so
transmission fluids stay cooler and
transmission life is prolonged.
Banks Diesel Tuner
99-03 Six-Gun (P/N 66513-66515)
94-03 Big Hoss (P/N 66505)
- Adds power safely to your
vehicle
- Engine and transmission
safeguards
- Change power levels on-the-fly
Thermocouple
- Add a temperature limiting function
to your Diesel Tuner
Banks QuickTurbo
94-97 (P/N 24450)
99-03 (P/N 24456-24457)
- More boost through the
powerband
- Does not over-boost
- Turbo-diesel efficiency
OttoMind Programmer
99-03 (P/N 66064)
- 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it will never be out of date
Banks TransCommand
94-97 (P/N 62560)
99-03 (P/N 62570)
- Produces smooth, firm, light
throttle shifts and solid, decisive
heavy-load shifts.
- Eliminates excessive clutch
slippage
Banks Git-Kit Systems
94-97 (P/N 48550)
99-03 (P/N 47401, 47511-47514)
Contains:
- Monster Exhaust
- Big Hoss Module
Banks Stinger Systems
94-97 Contains:
- Ram-Air Intake Filter
- Monster Exhaust
- Big Hoss Module
- TransCommand
99-03 Contains:
- Ram-Air Intake Filter
- Monster Exhaust
- Big Hoss Module
- Big Head Wastegate Actuator
Banks Stinger-Plus Systems
94-97 (P/N 48553-48554, 48559-48560)
Contains:
- Ram-Air Intake Filter
- Monster Exhaust
- Big Hoss Module
- TransCommand
- Quick Turbo Assembly
Banks PowerPack Systems
94-97 Contains:
- Ram-Air Intake Filter
- Monster Exhaust
- Big Hoss Module
- TransCommand
- Quick Turbo Assembly
- Techni-Cooler
99-03 Contains:
- Ram-Air Intake Filter
- Monster Exhaust
- Quick-Turbo
- TransCommand
- Techni-Cooler System
- Big Head Wastegate Actuator
Banks Six-Gun Bundle
99-03 (P/N 46594-46613)
Contains:
- Ram-Air Intake Filter
- Monster Exhaust
- Six-Gun Tuner
- TransCommand
- Big Head Wastegate Actuator
Banks Power Combo 1
99-03 Contains:
- Big Hoss Module
- TransCommand
- Big Head Wastegate Actuator
Banks Power Combo 2
99-03 Contains:
- Six-Gun Tuner
- TransCommand
- Big Head Wastegate Actuator
Banks Power Combo 3
99-03 Contains:
- Big Hoss Module
- Monster Exhaust
Banks Power Combo 4
99-03 Contains:
- Big Hoss Module
- TransCommand
- Big Head Wastegate Actuator
- Six-Gun Tuner
Banks Big Hoss Bundle
99-03 (P/N 46623-46643)
Contains:
- Ram-Air Intake Filter
- Monster Exhaust
- Six-Gun Tuner
- TransCommand
- Big Head Wastegate Actuator
- Techni-Cooler System
- Big Hoss Module
- Power Elbow
For More Information please call (800) 438-7693
or Visit us online @ www.bankspower.com
9 6 7 5 7 v. 2 . 0
|3
Banks Big Hoss™
Engine Calibration Module Installation
1. Disconnect all battery
ground cables.
2. Locate the ECU. 19941997 models only: The
ECU will be located in a
recess in the firewall on the
engine side, between the
steering column and the left
front fender. All that will be
visible is an elongated
electrical connector and
wire loom, surrounded by a
retainer plate attached with
two nuts. See Figure 1.
1999-2003 only: The ECU
will be located under the
dash toward the left-hand
side of the vehicle. It will be
housed in a black plastic
box bolted to the side of the
vehicle.
3. Loosen the bolt attaching
the electrical connector to
the ECU on the engine
compartment side.
4. 1994-1997 only:
Remove the two nuts and
retaining plate from against
the firewall. Pull the ECU out
of the firewall toward the
front of the vehicle. It may
be necessary to remove the
rearmost bolts attaching the
flexible inner fender well to
the body to provide
clearance to remove the
ECU. 1999-2003 only:
Loosen the two hex bolts on
the rear portion of the black
plastic box. Remove the box
and ECU from the vehicle
together. Pull the ECU out of
the plastic box.
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9 6 7 5 7 v. 2 . 0
5. Pry the plastic cap from
the rear of the ECU using a
small screwdriver, exposing
the printed circuit board
edge connector inside.
Retain the plastic cap.
Loosen and remove the six
bolts that hold the case of
the ECU together. Open the
case of the ECU being
careful not to lose the
plastic spacer or damage
any circuitry inside the ECU.
8. 1999-2003 only: Using a
6. Clean both sides of the
10. Check the operation of
the Big Hoss module and
ECU. The vehicle may not
start if the coating on the
ECU connector is not
completely removed or if
there is a mismatch of
codes. A quick indication of
module connections that
are not cleaned properly is
the “Wait to Start” indicator
will fail to light and the
“Check Engine” warning
indicator will stay lit after
the key is switched on. If
the engine fails to start,
re-clean the ECU connector,
reinstall the module and try
again.
connector. First, clean the
white grease off with a
tissue. Next, scrape the
clear silicone type coating
from the connector fingers
with the abrasive square
provided. It is very important
to clean both sides of the
board in order to have a
good connection between
the ECU and the Big Hoss
module. It is only necessary
to clean the connector
fingers. Be careful not to
damage any circuit traces
on the board further inside
the ECU.
7. Reassemble the ECU
case. Orient the Big Hoss
module so that its edges
line up with the edges of
the ECU case. Place the
module over the connector
and press firmly to set the
connection. DO NOT FORCE
the module onto the
connector, as damage may
result to either the ECU or
the module. Place a piece of
duct tape over the module,
fastening it firmly to the
ECU.
band saw or hacksaw, cut a
portion of the black plastic
case away allowing the
module to reside in its
proper location. See Figure
2.
9. Replace the ECU in its
original location and tighten
all bolts. Reattach the ECU
connector to the ECU and
reattach battery cables.
Figure 1
Figure 2
9 6 7 5 7 v. 2 . 0
|5
Gale Banks Engineering
546 Duggan Avenue • Azusa, ca 91702
(626) 969-9600 • Fax (626) 334-1743
Product Information & Sales: (800) 438-7693
bankspower.com
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