Owner`sManual
Owner’sManual
with Installation Instructions
Banks Billet™
Torque Converter
1995-2003 Ford Power Stroke 7.3L
Turbo-Diesel Pickups
Equipped with E4OD or 4R100 Transmissions
THIS MANUAL IS FOR USE WITH KITS 72521
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 96772 v.8.0
Also Available from Banks Power
for ‘94-97 Ford 7.3L
‘94-97 Ford 7.3L
Banks Monster® Exhaust System
Single (P/N 46296-46299)
- Increases exhaust flow, cuts
backpressure, lowers exhaust gas
temperatures (EGTs) and increases
power.
Banks Techni-Cooler® System
(P/N 25970)
- Provides increased air flow to the
engine by increasing air density for
more increased power, lower EGTs
and improved fuel economy.
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.
2
Banks Diesel Tuner
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
(P/N 24450)
- More boost through the
powerband
- Does not over-boost
- Turbo-diesel efficiency
Banks TransCommand
(P/N 62560)
- Produces smooth, firm, light
throttle shifts and solid, decisive
heavy-load shifts.
- Eliminates excessive clutch
slippage
Banks Git-Kit Systems
(P/N 48550)
Contains:
- Monster Exhaust
- Big Hoss Module
Banks Stinger Systems
Contains:
- Ram-Air Intake Filter
- Monster Exhaust
- Big Hoss Module
- TransCommand
Banks Stinger-Plus Systems
(P/N 48553-48554, 48559-48560)
Contains:
- Ram-Air Intake Filter
- Monster Exhaust
- Big Hoss Module
- TransCommand
- Quick Turbo Assembly
Banks PowerPack Systems
Contains:
- Ram-Air Intake Filter
- Monster Exhaust
- Big Hoss Module
- TransCommand
- Quick Turbo Assembly
- Techni-Cooler
For More Information please call (800) 438-7693
or Visit us online @ www.bankspower.com
96772 v.8.0
3
Also Available from Banks Power
for ‘99-03 Ford 7.3L
‘99-03 Ford 7.3L
Banks Power Elbow
(P/N 48651-48652, 48661-48663)
- Reduces stock outlet and pipe
backpressure
Banks Monster® Exhaust System
Sport (P/N 48789)
Single and Dual (P/N 48653-48660,
47391-47399)
- Increases exhaust flow, cuts
backpressure, lowers exhaust gas
temperatures (EGTs) and increases
power.
Banks Ram-Air Intake System
(P/N 96885)
- Increases your airflow over stock.
- Adds power, improves fuel economy,
lowers EGTs and reduces smoke.
Banks QuickTurbo
(P/N 24456-24457)
- More boost through the powerband
- Does not over-boost
- Turbo-diesel efficiency
Banks Brake
(P/N 55202-55207)
- Increases the stopping power of
your truck and extends the service
life of your brakes
Banks Techni-Cooler® System
(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.
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
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
4
96772 v.8.0
Banks SmartLock
(P/N 55266)
- Reduces wear on transmission
- Locks Torque Converter and raises
trans-line pressure
- Works with Banks Exhaust Brake
Banks TransCommand
(P/N 62570)
- Produces smooth, firm, lightthrottle shifts and solid, decisive
heavy-load shifts.
- Eliminates excessive clutch
slippage
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
Banks Git-Kit Systems
(P/N 47401, 47511-47514)
Contains:
- Monster Exhaust
- Big Hoss Module
Banks Stinger Systems
Contains:
- Ram-Air IntakeFilter
- Monster Exhaust
- Big Hoss Module
- Big Head Wastegate Actuator
Banks PowerPack Systems
Contains:
- Ram-Air Intake Filter
- Monster Exhaust
- Quick-Turbo
- TransCommand
- Techni-Cooler System
- Big Head Wastegate Actuator
Banks Six-Gun Bundle
(P/N 46594-46613)
Contains:
- Ram-Air Intake Filter
- Monster Exhaust
- Six-Gun Tuner
- TransCommand
- Big Head Wastegate Actuator
Banks Big Hoss Bundle
(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
Banks Power Combo 1
Contains:
- Big Hoss Module
- TransCommand
- Big Head Wastegate Actuator
Banks Power Combo 2
Contains:
- Six-Gun Tuner
- TransCommand
- Big Head Wastegate Actuator
Banks Power Combo 3
Contains:
- Big Hoss Module
- Monster Exhaust
Banks Power Combo 4
Contains:
- Big Hoss Module
- TransCommand
- Big Head Wastegate Actuator
- Six-Gun Tuner
For More Information please call (800) 438-7693
or Visit us online @ www.bankspower.com
96772 v.8.0
5
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
96772 v.8.0
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
• Metric box-end wrenches
• Standard and Phillips head
screwdrivers
• T45 Torx bit
• Standard and needle-nose pliers
• Clean shop towels or rags
• Transmission hoist
• Floor jack
• Drain pan
• 320-400 grit sandpaper
• Measuring ruler
• Pry bar or channel lock pliers
• Grease pen
• Foot-pound torque wrenches
• Multipurpose Grease
Highly recommended tools and
supplies:
• Flywheel rotating tool
• Penetrating oil or light lubricant
spray
Notice To Installer:
1. In order for the Banks Torque
Converter to function as designed, the
transmission must be re-calibrated to
increase transmission line pressure
and adjust shift timing. Banks highly
recommends installing the Banks
Transcommand in conjunction with
the Banks Torque Converter. Failure
to re-calibrate the transmission may
lead to excess lock-up clutch wear
and poor shift performance. Banks
Transcommand (E4OD, P.N. 62560;
4R100, P.N. 62570) is available from
Gale Banks Engineering or through
authorized Banks dealers.
2. Banks also recommends replacing
your transmission fluid, transmission
fluid filter, and transmission pan
gasket. Failure to service transmission
fluid may result in torque converter
damage.
Banks Billet Torque
Converter is designed for
a 6-stud, Ford 7.3L diesel
applications
You can verify the number of studs
on your existing torque converter by
removing the inspection cover on
the lower-front of the transmission
and counting the studs on the torque
converter (see Step 13 in installation
procedure).
• For 4x4 models: Second
transmission hoist
• Transmission hoist adapter
• Torque converter holding tool
• Transmission fluid filter
• Transmission pan gasket
96772 v.8.0
5
Installation Procedure
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. For Excursions, remove the six (6)
retaining bolts around the belly pan
and retain for reassembly. Remove the
belly pan from the vehicle.
Figure 1
6
96772 v.8.0
4. Remove the 14mm bolt located on
the bell housing of the passenger side
of the transmission that secures the
transmission oil filler tube. Remove the
oil filler tube.
5. 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.
6. Mark the rear axle, driveshaft, and
transmission / transfer case output
flange (if so equipped) for re-alignment
during reassembly. Disconnect the
driveshaft from the rear axle flange
(some models require either a T-45
torx bit or a 12mm 12-point socket /
box-end wrench). (See Figure 1).
Note: On models using strap-type (vs.
flange) attachment for the U-joint to
the rear axle yoke, take care to keep
the bearing caps on the U-joint when
removing the driveshaft – wrapping the
bearing caps with electrical tape or a
similar material will keep the bearing
caps from separating from the spider.
7. Support the driveshaft, either from
below with a stand or above with a
length of wire from the chassis. For
four-wheel drive vehicles, disconnect
the rear driveshaft from the transfer
case or transmission. For two (2)
piece driveshaft models, remove the
two (2) 9⁄ 16” bolts on the drive shaft
bearing support mount linking the two
driveshaft halves.
8. Taking care to not let the slip
yoke in the driveshaft extend too far
and separate, lower the driveshaft
assembly and slide it rearward off of
the transmission. Position the drain
pan below the transmission/transfer
case output shaft to contain any fluid
that may drain once the driveshaft is
removed.
9. For 4x4 models, the transfer case
will need to be removed.
A) Mark and disconnect the front
driveshaft from the transfer case.
B) Remove the manual shift linkage.
11. Remove the transmission range
(TR) sensor by:
A) Disconnect the shift cable from the
manual lever.
B) Disconnect the cable housing from
the bracket. (see Figure 2).
12. Disconnect all connectors on
the transmission including digital
transmission range, solenoid body
connector, turbine shaft speed (TSS)
and output shaft speed (OSS) sensors.
13. To access the converter-to-
flexplate nuts, remove and retain the
bolts mounting the inspection cover and
remove the inspection cover. Rotate the
flywheel until the converter-to-flexplate
nuts are accessible. Remove each of
the nuts - a flywheel rotating tool or pry
bar may assist with the flexplate nuts
removal (see Figure 3).
14. Raise the transmission hoist
under the transmission (if necessary,
mount the E4OD transmission
adapter onto the transmission hoist).
Remove and retain the transmission
crossmember bolts from the frame
rails. Remove the transmission
crossmember (see Figure 4).
C) Disconnect the three (3) position
switch harness connector and gear
motor encoder harness connectors.
15.
D) Position a transmission jack or
equivalent under the transfer case and
slightly lift the transfer case to release
tension on the retaining bolts.
16. Remove the six (6) transmission
E) Remove the six (6) mounting bolts
connecting the transfer case to the
extension housing and retain for
reassembly. Remove the transfer case
from the vehicle.
10. If equipped, remove the
transmission mounted parking
brake assembly and power take-off
unit (PTO).
If necessary, remove the
exhaust components surrounding the
transmission.
mounting bolts from the transmission
flange and retain for reassembly. Rock
the transmission to disengage it from
the locator dowels.
17. Remove the transmission and the
Torque Converter together from the
engine. If available, install a torque
converter holding tool.
CAUTION: When removing the
transmission, use care to avoid
obstructions. If equipped, do not
use the cooler bypass valve (CBV)
as a handle or support for the hoist
96772 v.8.0
7
Figure 2
Figure 3
8
96772 v.8.0
Figure 4
strap. Be sure the torque converter
is stable inside the transmission.
should be replaced prior to installing the
new torque converter.
18. Place a suitable drain pan under
20. Carefully remove the Banks Billet
the front of the transmission.
CAUTION: Verify that the
transmission is secured to the
lifting device. When the torque
converter is removed, the
transmission’s center of gravity
will shift and the transmission may
become unstable.
19. If previously used, remove the
torque converter holding tool. 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
Torque Converter from the shipping
container. Be careful not to damage
the shipping container, as it will be
used to return the factory torque
converter to Gale Banks Engineering.
21. 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 hub and/or
notches with 320⁄400 grit sandpaper
and crocus cloth – clean the converter
afterwards to remove any foreign
particles as necessary.
22. Position the Banks Billet
Torque Converter with the drive hub
up and pour one (1) quart of the
96772 v.8.0
9
components.
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.
29. Reinstall the transmission
CAUTION: When installing the
Banks Billet Torque Converter, be
careful to not damage the pump
gear O-ring or hub seal.
30. Rotate the torque converter and
23. Lift the Banks Billet Torque
Converter and position it in front of
the transmission input shaft. Turn the
torque converter as needed to index
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. Use a straightedge
to verify there is a gap between the
converter pilot hub face and housing
(see Figure 5). This ensures that the
Torque Converter is fully engaged to
the input shaft and the drive hub is
sealed properly.
24. Retain the torque converter with
the converter holding tool, if available.
25. Before installing the transmission
into the vehicle, Gale Banks
Engineering recommends flushing and
thoroughly cleaning the transmission
cooler, lines, and cooler bypass valve.
Lubricating the converter pilot hub
with multipurpose grease is also
recommended.
26. Position the transmission
near the engine and remove the
converter holding tool, if used. Align
the converter studs with the engine
flexplate. Install the transmission to
the engine.
crossmember onto the frame rails.
Reinstall and torque the crossmember
bolts to 60 ft-lbs (see Figure 4).
install the NEW (supplied) converterto-flexplate 3⁄ 8”-24 nuts. Evenly torque
the nuts to 30 ft-lbs (see Figure 3).
31. Reinstall the inspection cover and
torque the bolts to 15 ft-lbs.
32. Verify the transmission is secured
to the crossmember and remove the
transmission hoist.
Note: The transmission fluid,
transmission fluid filter and pan gasket
should be serviced at this time. Follow
the instructions in the vehicles owner’s
manual for servicing the transmission.
33. For 4x4 models, reinstall the
transfer case.
A) Hoist the transfer case to the
extension housing. Reinstall the six (6)
mounting bolts and torque to 37 ft-lbs.
B) Reconnect the three (3) position
switch harness connector and
gearmotor encoder harness
connectors.
C) Align and reinstall the front
driveshaft to the transfer case.
D) Reinstall the manual shift linkage
and remove the transfer case hoist.
34. Re-align and re-attach the front of
the rear driveshaft to the transmission
or transfer case output shaft / flange.
27. Reinstall the six (6) transmission
On flanged models, only tighten the
attachment bolts finger-tight at this
time.
28. If previously removed, reinstall
For models equipped with a two (2)
piece driveshaft, re-install the center
bearing support and hand-tighten the
mounting bolts.
mounting bolts through the
transmission mounting flange and into
the engine. Torque evenly to 45 ft-lbs.
any disconnected exhaust system
10
96772 v.8.0
Figure 5
96772 v.8.0
11
CAUTION – On models using a
mounting flange for driveshaft
attachment, the driveshaft yokes
fit tightly onto the flange pilots.
To make sure that the yoke seats
squarely onto the flange, evenly
tighten the bolts in a cross pattern.
43. Fill the transmission with the
35. Tighten the driveshaft-to-
Note: To recalibrate your transmission,
the Banks TransCommand should be
installed at this time, or another method
of increasing transmission line pressure
must be used. Failure to install the Banks
TransCommand may result in excessive
clutch wear.
transmission bolts to 76 ft-lbs (if so
equipped).
36. For models with strap-type
rear axle pinion yokes, remove the
electrical tape retaining the bearing
caps (if used) on the rear of the
driveshaft and re-attach it to the rear
axle. Tighten the fasteners to 26 ft-lbs.
37. For models with flange-type
rear axle pinion mounts, reinstall the
fasteners and torque to 82 ft-lbs.
38. Tighten the driveshaft center
support bearing bolts to 47 ft-lbs (if so
equipped).
39. If applicable, reinstall the
transmission mounted parking brake
assembly and power take-off unit
(PTO).
40. Reconnect all connectors to the
transmission including the solenoid
body connector, turbine shaft speed
(TSS) and output shaft speed (OSS)
sensors. Reconnect the transmission
range (TR) sensor by:
A) Reconnect the cable housing to the
mounting bracket.
B) Reconnect the shift cable to the
manual lever. (see Figure 2)
41. Reinstall the transmission cooler
lines to the transmission.
42. Verify that all previously removed
components are reconnected, all
tools used are accounted for and all
bolts are tightened to manufacturer’s
specifications.
12
96772 v.8.0
manufacturer’s specified transmission
fluid.
CAUTION: Do not overfill
transmission fluid. Check the fluid
level periodically during refilling.
44. Reconnect the battery cable(s).
45. Start the vehicle and allow
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.
46. Locate the serial number sticker
included in the torque converter
installation kit. This sticker is provided
as a means of allowing Banks
Technical Support to rapidly identify
your individual torque converter
should the need arise. Gale Banks
Engineering recommends permanently
affixing it to a safe location on the
vehicle, such as the inside of the glove
box lid or door jamb, where it can be
quickly located and read. Installation
of the Banks Billet Torque Converter is
now complete.
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.
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.
Verify that the Torque Converter is
secure in the shipping container.
96772 v.8.0
13
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
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