Owner`sManual
Owner’sManual
with Installation Instructions
Banks Billet™
Torque Converter
2003-2007 Ford Power Stroke 6.0L
Turbo-Diesel Pickups
Equipped with TorqShift™ Transmissions
2005-2009 Ford 6.8L V10 Gas
Pickup, SUV & Motorhome
Equipped with 5R110 Transmissions
THIS MANUAL IS FOR USE WITH KITS 72522
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
©2016 Gale Banks Engineering
06/13/16 PN 96799 v.4.0
Also Available from Banks Power
03-07 Ford 6.0L
Banks iQ System
(P/N 61151-61152)
- 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.
Banks Ram-Air Intake System
(P/N 42155)
- Increases your airflow over stock.
- Adds power, improves fuel economy,
lowers EGTs and reduces smoke.
2
96799 v.4.0
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 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/ switch (P/N 61023)
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
Banks Speed-Loader
(P/N 62988)
- Furthers the power output of the
Banks Six-Gun and provides EGT
limiting safety.
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
OttoMind Programmer
(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
For More Information please call (800) 438-7693
or Visit us online @ www.bankspower.com
96799 v.4.0
3
General Installation Practices
Dear Customer,
If you have any questions
concerning the installation
of your Banks Billet™ Torque
Converter, please contact our
Technical Service Hotline at
(888) 839-7200 between 7:00 am
and 5:00 pm (PST). If you have
any questions related to shipping
or billing, please contact our
Customer Service Department at
(888) 839-5600.
Thank you.
1. Familiarize yourself with the
installation procedure by reading the
installation manual before starting
work.
2. Throughout this manual, the
left side of the vehicle refers to the
driver’s side, and the right side refers
to the passenger’s side.
3. Disconnect the negative (ground)
cable from the battery (or batteries, if
there are two) before beginning work.
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 your
work area and tools clean to avoid
possible entry of dirt into the drivetrain
components.
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
4
96799 v.4.0
the vehicle, 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 securely blocked.
Caution! Do not use floor jacks to
support the vehicle while working
under it. Do not support the vehicle
using concrete blocks, masonry
or any other item not intended
specifically for this use.
7. Installing the Banks Torque
Converter requires removal of the
transmission from the vehicle. Heavy
tooling such as a transmission jack
and an automotive hoist or ampleheight jack stands are required.
Professional installation by a properly
equipped shop is recommended.
Failure to follow all installation
instructions during Torque Converter
install can result in bodily injury and/or
expensive damage to the transmission
and surrounding components.
8. The transmission and torque
converter must be removed as an
assembly to avoid damage to the
converter drive plate, pump bushing
and oil seal.
9. Before installing the Banks
Torque Converter, verify that your
transmission is in good operating
condition. Transmission problems
such as harsh or delayed engagement
when shifting into Drive or Reverse, no
Drive or Reverse range, erratic shifting,
grating or scraping noises, or lack of
up and/or downshifting can lead to
torque converter damage. If necessary,
have your transmission repaired
or overhauled before installing the
converter.
10. If your transmission has just been
rebuilt, make sure to flush all old fluid
from the vehicle’s transmission cooler
and connecting lines before reinstalling
your transmission.
Tools Required:
• 3⁄ 8” and 1⁄ 2” drive ratchets with
metric sockets including 1⁄ 2” and 3⁄ 8”
drive extension
Highly recommended tools and
supplies:
• Flywheel rotating tool
• Metric box-end wrenches
• Penetrating oil or light lubricant
spray
• Standard and Phillips head
screwdrivers
• For 4x4 models: Second
transmission hoist
• Standard and needle-nose pliers
• Transmission hoist adapter
• Clean shop towels or rags
• Torque converter holding tool
• Transmission hoist
• Transmission fluid filters
• Floor jack
• Transmission pan gasket
• Drain pan
• 320-400 grit sandpaper
Notice To Installer:
• Measuring ruler
Banks recommends replacing your
transmission fluid, transmission fluid
filters, and transmission pan gasket.
Failure to service transmission
fluid may result in torque converter
damage.
• Pry bar or channel lock pliers
• Grease pen
• Foot-pound torque wrenches
• Transgel Grease
96799 v.4.0
5
Installation Procedure
Banks Billet Torque Converter
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 high enough to
remove the transmission 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.
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.
3. Remove the rear drive shaft.
A) Mark the driveshaft and the
transmission or transfer case
output shaft/ circular flange and
mark the driveshaft at the rear
axle pinion flange to help with
re-alignment during reassembly.
See Figure 1 & 2.
B) For models with circular flange,
loosen and remove the bolts
connecting the driveshaft to the
transmission or transfer case
circular flange.
C) For models with three piece
driveshaft, loosen and remove
the bolts and u-joint retainers to
disconnect the drive shaft from the
coupling shaft.
D) For models with two and three
piece driveshaft, remove the center
bearing support bolts. See
Figure 3.
Figure 1 For Vehicles Without Circular Flange
6
96799 v.4.0
Figure 2 For Vehicles with Circular Flange
Figure 3 For Two and Three Piece Driveshaft remove Center Support Bearing.
96799 v.4.0
7
Figure 4
Figure 5
8
96799 v.4.0
Figure 6
NOTE: For models with three piece
driveshaft, the coupling shaft will
not be removed from the rear axle
pinion flange. Support the coupling
shaft with a length of wire from the
chase and remove the driveshaft
from the vehicle.
E) Loosen and remove the bolts
and u-joint retainers on the
driveshaft to the rear axle pinion
flange. For vehicles with circular
flange drive shaft, loosen and
remove the bolts on the rear axle
pinion flange. Retain all hardware
for reuse.
F) Lower the driveshaft from the
rear axle pinion flange and slide
it rearward off the transmission
output shaft. For vehicles with a
circular flange, use a small pry tool
to help disconnect the driveshaft
yoke to the rear axle pinion flange.
See Figure 4.
G) Position the drain pan below
the transmission/transfer case
output shaft to contain any fluid
that may drain once the driveshaft
is removed.
NOTE: On models using strap-type
(vs. flange) attachment, take care
to keep the bearing caps on the
U-joint spider when removing the
driveshaft. Wrap the bearing caps
with electrical tape or a similar
material to keep the bearing caps
from separating from the spider.
4. Raise the transmission jack under
the transmission.
5. Remove the wire harness from the
rear crossmember.
6. Remove the rear transmission
mount nuts. See Figure 5.
7. Disconnect and remove the shift
cable from the manual lever. Loosen
and remove the bolts to the shift
cable housing bracket and secure the
cable away from the transmission. See
Figure 6.
96799 v.4.0
9
8. Loosen the bolt and disconnect the
solenoid body electrical connector.
See Figure 7.
9. Disconnect the output shaft speed
(OSS) sensor electrical connector and
the turbine shaft and intermediate
shaft combination speed sensor
electrical connector. See Figure 8.
10. Disconnect the left and right hand
wire harness from the sides of the
transmission.
11. Remove the crossmember
bracket bolts on the right side of
the vehicle. Loosen the bolts on
the crossmember and remove the
crossmember from the vehicle. Retain
all hardware for reassembly. See
Figure 9.
12. Remove the exhaust components
surrounding the transmission.
13. Remove the starter motor.
14. For 4x4 models, the transfer case
will need to be removed.
Figure 7
10
96799 v.4.0
A) Mark and disconnect the front
driveshaft from the transfer case.
B) Remove the manual shift
linkage.
C) Disconnect the switch electrical
connector, the gear motor
encoder assembly electrical
connector, and the gear motor
electrical connector. Secure the
connector harness away from the
transmission.
D) Disconnect the vent hose from
the transfer case.
E) Position a transmission jack or
equivalent under the transfer case
and slightly lift the transfer case
to release tension on the retaining
bolts.
F) Remove the six (6) mounting
bolts connecting the transfer case
to the extension housing and retain
for reassembly. Slide the transfer
case rearward and remove the
transfer case from the vehicle.
Figure 8
Figure 9
96799 v.4.0
11
15. For models with dual generators,
16. To access the converter nuts,
WARNING: Torque Converter can
slide off the turbine shaft. Secure
the converter when removing
the transmission and torque
converter assembly from the
engine.
17. Remove the torque converter
NOTE: The fluid filler tube will detach
from the transmission when lowering
the transmission.
remove the outer accessory drive belt
from the crankshaft pulley by rotating
the tensioner.
remove the cylinder block opening
cover. See Figure 10.
nuts by rotating the crankshaft pulley.
NOTE: A suitable strap wrench can be
used to rotate the crankshaft pulley
with the drive belt removed.
18. A drain pan should be positioned
under the working area. Disconnect
the transmission fluid cooler tubes
located on the right side of the
transmission and allow them to drain
into the drain pan. See Figure 11.
21. Remove the nine (9) transmission
mounting bolts.
22. Carefully slide the transmission
and torque converter assembly
rearward.
Figure 10
12
96799 v.4.0
23. Lower the transmission and
remove it from under the vehicle.
24. Once the transmission and torque
converter assembly are removed,
place a suitable drain pan under
the converter housing end of the
transmission.
CAUTION: Verify that the
transmission is secured to the
lifting device. When torque
converter is removed, the
transmission’s center of gravity
will shift and transmission may
become unstable.
Figure 11 Disconnect Transmission Fluid cooler Tubes
96799 v.4.0
13
25. Evenly pull on the torque
converter to remove it - avoid wiggling
or cocking the converter sideways as
much as possible to prevent damage
to the transmission input shaft and
seals.
NOTE: Inspect the oil seal on the front
pump of the transmission. If there are
signs of leakage or damage, the seal
should be replaced prior to installing
the new torque converter.
26. Carefully remove the Banks Billet
Torque converter from the shipping
container. Be careful not to damage
the shipping container, as it will be
used to return the factory toque
converter to Gale Banks Engineering.
27. To avoid pump seal damage
during converter installation, inspect
the Banks Billet Torque Converter hub
and hub drive notches for sharp edges,
burrs, scratches, or nicks. It may be
necessary to polish the hub and/or
notches with 320/400 grit sandpaper
and crocus cloth. Clean the converter
14
96799 v.4.0
afterwards to remove any foreign
particles as necessary.
28. Position the Banks Billet
Torque Converter with the drive hub
up and pour one (1) quart of the
manufacturer’s specified transmission
fluid into the drive hub. Use a small
amount to coat the splines of the input
shaft protruding from the transmission.
CAUTION: When installing the
Banks Billet Torque Converter, be
careful to not damage the pump
gear O-ring or hub seal.
29. Before installing the Banks Billet
Torque Converter, it is recommended
to drain the transmission fluid, replace
transmission oil filters and pan gasket,
flushing and thoroughly cleaning the
transmission cooler lines and bypass
value, and to lubricate the converter
pilot hub with transgel grease.
30. Lift the Banks Billet Torque
Converter and position it in front of
the transmission input shaft. Turn the
torque converter as needed to index
Figure 1214
96799 v.4.0
15
properly and engage the transmission
input shaft splines, then carefully
work the torque converter onto the
transmission input shaft until it is
recessed behind the front transmission
mounting flange.
31. Check converter seating with a
ruler and straightedge to verify there is
a gap between the converter pilot hub
face and housing. See Figure 12. This
ensures that the Torque Converter is
fully engaged to the input shaft and
the drive hub is sealed properly.
32.
When raising the transmission
align the fluid filler tube with the stub
tube on the transmission using the
fluid indicator as a guide.
33. Position the transmission near
the engine and align the converter
studs with the engine flexplate. Move
the transmission towards the engine
and install the transmission to the
engine.
WARNING: Torque Converter can
slide off the turbine shaft. Secure
the converter when installing the
transmission and torque converter
assembly from the engine.
34. Reinstall the nine (9) transmission
mounting bolts through the
transmission mounting flange and into
the engine. Torque evenly to 35 ft-lbs.
37. Reinstall the transmission cooler
lines to the transmission. Torque the
nuts to 30 ft-lbs
38. Rotate the torque converter and
install the NEW (supplied) converter-toflexplate 3/8”-24 nuts. Evenly torque
the nuts to 26 ft-lbs.
39. Reinstall the cylinder block
opening cover.
NOTE: Reinstall the drive belt if
previously removed.
40. For models with dual generators,
reinstall the outer accessory drive belt
16
96799 v.4.0
to the crankshaft pulley by rotating the
tensioner.
41. For 4x4 models, reinstall the
transfer case.
A) Hoist the transfer case and align
to the extension housing. Slide
the transfer case into place and
reinstall the six (6) mounting bolts.
Torque evenly to 37 ft-lbs.
B) Reconnect the vent hose to the
transfer case.
C) Reconnect the switch electrical
connector, the gear motor encoder
assembly electrical connector,
and the gear motor electrical
connector.
D) Reinstall the manual shift
linkage.
E) Align and reinstall the front
driveshaft to the transfer case.
F) Remove the transfer case hoist.
42. Reinstall the exhaust components
surrounding the transmission.
44. Reinstall the crossmember to the
vehicle. Reinstall the crossmember
bracket bolts on the right side of the
vehicle. Tighten all bolts to 60 ft-lbs.
45. Reconnect the left and right
hand wire harness to the side of the
transmission.
46. Reconnect the Turbine shaft
and intermediate shaft combination
speed sensor electrical connector and
the output shaft speed (OSS) sensor
electrical connector.
47. Reconnect the solenoid body
electrical connector and secure with
the factory bolt.
48. Reinstall the shift cable housing
bracket to the transmission. Torque
bolts to 18 ft-lbs. Reconnect the shift
cable to the manual lever.
49. Reinstall the rear transmission
mount nuts. Torque nuts to 60 ft-lbs.
50. Secure the rear wire harness to
the crossmember.
51. Verify the transmission is secured
to the crossmember and remove the
transmission hoist.
52. Reinstall the rear drive shaft.
A) Re-align and re-attach the
driveshaft to the transmission or
transfer case output shaft/ flange.
For flanged models only handtighten the attachment bolts.
B) Re-align and re-attach the rear
of the driveshaft to the rear axle
pinion flange. Torque the bolts to
76 ft-lbs. For models with straptype rear axle pinion yokes, remove
the electrical tape retaining the
bearing caps on the rear of the
driveshaft and re-attach it to the
rear axle or coupling shaft ,for
three piece driveshaft, using the
u-joint retainer and bolts. Torque
bolts to 26 ft-lbs.
engine to reach normal operating
temperatures. With the vehicle
lightly loaded, accelerate gently and
allow the torque converter to lock
and unlock a minimum of fifteen
(15) times. This can be achieved
by lightly accelerating from 20
MPH to 50 MPH multiple times. If
possible, monitor transmission fluid
temperature to verify proper torque
converter and transmission operation.
Fluid temperatures much higher
than normal can be indicative of a
malfunctioning transmission and/or
torque converter. Check transmission
fluid level and add the manufacturer’s
specified type of fluid as needed.
Installation of the Banks Billet Torque
Converter is now complete.
C) For two and three piece
driveshaft, connect the drive shaft
center support bearing bolts.
Torque the bolt to 47 ft-lbs.
53. Verify that all previously removed
components are reconnected, all
tools used are accounted for and all
bolts are tightened to manufacture
specifications.
54. Lower the vehicle and fill the
transmission with manufacturer’s
specified transmission fluid.
CAUTION: Do not overfill
transmission fluid. Check the
fluid level periodically during
refilling.
55. Reconnect the battery cable(s).
56. Start the vehicle and allow
96799 v.4.0
17
To receive a core charge refund, complete
the following steps.
1. You will notice that you have been
charged a $250.00 refundable core
charge for your Banks Billet Torque
Converter. In order to receive a refund
on the core charge you must send us
a good rebuildable core. Please follow
these important instructions.
7. Locate the return shipping label
2. Do not discard or destroy the
customer service line (888) 839-5600
with your original invoice number to
receive an RMA number. Write the
RMA number on the label in the space
provided.
shipping container that your new
torque converter came in.
3. After installation of your new
torque converter, DRAIN ALL FLUID
from your old torque converter by
allowing it to sit upside-down in
a suitable drain pain or container
overnight.
CAUTION: Failure to properly
drain the converter may result
in shipping refusal or other
consequences related to shipping
hazardous material.
4. Install supplied plug on old torque
converter input hub and wrap it in the
supplied plastic bag.
5. Pack the torque converter into the
Banks shipping container. If applicable,
place the foam insulation around the
torque converter to prevent damage
during shipping.
6. Reseal the shipping container.
Verify that the Torque Converter is
secure in the shipping container.
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
included in the Banks Billet Torque
Converter package and affix it to the
outside of the shipping container so
that it completely covers the previous
shipping label.
8. Call Gale Banks Engineering
9. Ship the core to the address shown
on the label.
NOTE: Any charges incurred to return
the core are the responsibility of the
customer. If your return-shipping
label is missing or damaged, ship the
packaged torque converter to:
GALE BANKS ENGINEERING
1800 N 30th Avenue
Melrose Park IL 60160
Thank you for your cooperation with
the core return process, and for
choosing Gale Banks Engineering.
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement