Owner`sManual
Owner’sManual
with Installation instructions
Banks Six-Gun
Diesel Tuner
®
2003-2004 (235 HP, 250 HP and 305 HP)
Dodge 5.9L Cummins
(24-valve) ISB Pickup Trucks
THIS MANUAL IS FOR USE WITH SYSTEMS 49525, 49526, 49527,
49528, 49530 , 49531, 62977 & 62978
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
109/20/12 PN 96448 v.12.0
Products available from Banks Power
for 03-07 Dodge 5.9L
03-07 Dodge 5.9L
Banks iQ System
(P/N 61148-61149)
Note: Must upgrade Six-Gun Tuner to
63726 to use with Banks iQ.
- 5” touchscreen interface that can
control the Banks Diesel Tuner 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
Single (P/N 48640-48643, 48700,
48701, 48708)
Duals (P/N 48702-48707, 48709)
Sport (P/N 48777-48780)
- Increases exhaust flow, cuts
backpressure, lowers exhaust gas
temperatures (EGTs) and increases
power.
Banks Ram-Air Intake System
(P/N 42145)
- Increases your airflow over stock.
- Adds power, improves fuel economy,
lowers EGTs and reduces smoke.
2
96448 v.12.0
Banks Ram-Air Intake Super-Scoop
(P/N 42190-42191)
- Adds cooler denser air to the RamAir Intake housing, further
increasing fuel economy, reducing
smoke and lowers EGTs.
Banks Monster-Ram
(P/N 42765-42766)
- Increased flow from intercooler
- Raises boost without increasing
backpressure at the turbine
Big Hoss Intake Manifold System
(P/N 42747)
- Increases flow and provides more
uniform air distribution to the
engine for more available power at
a given boost level.
Banks Exhaust Brake
(P/N 55222-55229)
- Increases the stopping power of
your truck and extends the service
life of your brakes
Banks SmartLock
(P/N 55270)
- Reduces wear on transmission
- Locks Torque Converter and raises
trans-line pressure
- Works with Banks Exhaust Brake
Boost and Pyro Gauges
(P/N 64507)
- Keep your engine safe by
monitoring vital engine parameters.
Banks Billet Torque Converter
(P/N 72515)
- Higher torque capacity over stock
- Lockup clutch is slip-resistant so
transmission fluids stay cooler and
transmission life is prolonged.
Banks Bullet
(P/N 66522-66523)
- Adds power safely to your vehicle
- Displays critical engine functions
- Engine safeguards
- Change power levels on-the-fly
Banks Techni-Cooler® System
(P/N 25980-25981)
- Provides increased air flow to the
engine by increasing air density for
more increased power, lower EGTs
and improved fuel economy.
Thermocouple
- Add a temperature limiting function
to your Diesel Tuner.
Banks BigHead® Actuator
(P/N 24331)
- Achieves a higher peak boost over
stock and gives you precise
boost control that gives you crisp
acceleration and more mid-range
pulling power.
anks Stinger Systems
B
(P/N 49692-49699, 49708-49711,
49716-49721)
Contains:
- Ram-Air Intake system
- Monster Exhaust (single or dual)
- EconoMind Tuner w/ Banks iQ
- Big Head Wastegate Actuator
Banks PowerPack Systems
(P/N 49700-49707, 49712-49715,
49722-49727)
Contains:
- Ram-Air Intake system
- Monster Exhaust (single or dual)
- EconoMind Tuner w/ Banks iQ
- Big Head Wastegate Actuator
- Monster-Ram
- Techni-Cooler System
Banks Six-Gun Bundle
(P/N 49728-49735, 49744-49747,
49752-49757)
Contains:
- Ram-Air Intake system
- Monster Exhaust (single or dual)
- Six-Gun Tuner w/ Banks iQ
- Big Head Wastegate Actuator
Banks Big Hoss Bundle
(P/N 49736-49743, 49748-49751,
49758-49763)
Contains:
- Ram-Air Intake system
- Monster Exhaust (single or dual)
- Six-Gun Tuner w/ Banks iQ
- Big Head Wastegate Actuator
- Monster-Ram
- Techni-Cooler System
For More Information please call (888) 635-4565
or Visit us online @ www.bankspower.com
96448 v.12.0
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
96448 v.12.0
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
aggress 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.
The Warranty is Limited to two (2)
years from the date of sale and is
limited solely to the parts contained
within the product’s kit. 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 3 . . . . . . . . . . . . . . . . . . . . . 23
Optional Thermocouple installation
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.
Section 5 . . . . . . . . . . . . . . . . . . . . . 27
Engine Power Rating
Learning Procedure
IN THE EVENT THAT THE BUYER
DOES NOT AGREE WITH THIS
AGREEMENT: THE BUYER
MAY PROMPTLY RETURN THIS
PRODUCT, IN A NEW AND
UNUSED CONDITION, WITH A
DATED PROOF OF PURCHASE,
TO THE PLACE OF PURCHASE
WITHIN THIRTY (30) DAYS FROM
DATE OF PURCHASE FOR A FULL
REFUND.
Disclaimer of Liability . . . . . . . . . . 4
& Warranty
General Installation Practices . . . 6
Section 1 . . . . . . . . . . . . . . . . . . . . . . 9
Six-Gun Diesel Tuner Installation
Section 2 . . . . . . . . . . . . . . . . . . . . 20
Installation of the Six-Gun Power Level
Selector Switch
Section 4 . . . . . . . . . . . . . . . . . . . . 25
Performing Transmission
Learning Procedure
Section 6 . . . . . . . . . . . . . . . . . . . . . 29
Checking Engine
Performance
Section 7 . . . . . . . . . . . . . . . . . . . . 30
Mounting the
Six-Gun Module
Section 8 . . . . . . . . . . . . . . . . . . . . 31
Troubleshooting
Section 9 . . . . . . . . . . . . . . . . . . . . . 33
Clearing Learned
Transmission Procedure
THE INSTALLATION OF THIS
PRODUCT INDICATES THAT
THE BUYER HAS READ
AND UNDERSTANDS THIS
AGREEMENT AND ACCEPTS ITS
TERMS AND CONDITIONS.
96448 v.12.0
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) 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.
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 1350º F for more
than a few seconds. Elevated EGT
can damage the turbocharger and the
engine.
Also, the factory clutch or torque
converter will need to be upgraded to
an aftermarket unit that can handle
the increased torque and horsepower
of the higher levels. Failure to upgrade
the clutch or torque converter prior
to using the upper levels while the
vehicle is loaded may result in damage
6
96448 v.12.0
to the factory clutch or torque.
Banks is NOT responsible for clutch,
torque converter and/or transmission
damage.
Note: Before proceeding with these
instructions, please carefully read
the DISCLAIMER OF LIABILITY and
LIMITATION OF WARRANTY statement
located on page 4 of this manual.
1. For ease of installation of your
Banks Six-Gun, familiarize yourself
with the procedures by reading the
entire manual before starting work.
2. Disconnect the ground cable from
the battery before beginning work. If
there are two batteries, disconnect
both.
3. 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.
4. 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 hand 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.
5. The installation should be
performed at a time when the vehicle
has been allowed to completely cool.
This installation requires the installer
to work near surfaces that may remain
hot after the vehicle has been run.
Failure to allow the vehicle to cool
may result in personal injury.
Tools Required:
6. During installation, keep your work
These tools are necessary for the
installation unless otherwise specified.
7. Save this Owner’s Manual as a
• 1⁄ 4” and 3⁄ 8” drive ratchets with inch
and metric sockets including 5⁄ 16”,
7⁄ 16” deep 1⁄ 4” drive sockets and a 1⁄ 4”
drive extension
8. Banks recommends that a
• Inch and metric combination or
open-end wrenches
area and components clean to avoid
possible dirt entry into the engine.
reference for system maintenance and
service.
Pyrometer (EGT) gauge and a Boost
gauge be installed with the SixGun Diesel Tuner to help monitor
performance and exhaust gas
temperature of the vehicle (see part
numbers below). To further increase
engine life by lower EGT’s, Banks also
recommends installing the following
airflow improvements:
Airflow Improvements:
1. Banks Monster Exhaust,
235-, 250- and 305-hp Rated Engines . Std. Cab Long Bed w/ Cat . . . 48640
Quad Cab Short Bed w/ Cat . . 48640
Std. Cab Long Bed w/o Cat . . 48641
Quad Cab Short Bed w/o Cat 48641
Quad Cab Long Bed w/ Cat . . 48642
Quad Cab Long Bed w/o Cat . 48643 2. Banks BigHead® Actuator . . . . . . 24331
3. Banks Ram-Air®
Filter . . . . . . . . . . . . . . . . . . . . . 41028
Service Kit . . . . . . . . . . . . . . . . 90094
Gauges:
4. Gauge Assembly
Boost and Pyro* . . . . . . . . . . . 64507
5. Thermocouple . . . . . . . . . . . . . . 63042
6. Lead wire . . . . . . . . . . . . . . . . . . . 63061
7. Turbine Inlet Gasket* . . . . . . . . . 93033
* also available separately
• Standard and Phillips head
screwdrivers
• Standard and needle-nose pliers
• Pocket or X-Acto knife
• Clean shop towels or rags
• Drill motor
• 1⁄ 8” and 3⁄ 8” drill bits
• Wire crimping/stripping tool
Tools Required for Optional SpeedLoader Installation:
• 7⁄ 16” drill bit
• Tap Handle
• 1⁄ 4” NPT tap
• 12mm, 12-point socket & wrench
Highly recommended tools and
supplies:
• Multimeter or 12-volt test light
• Heat gun
9. For ease of installation of your Six-
Gun Diesel Tuner, refer to the Installation
Flow Chart on page 8 and the Table of
Contents on page 5 for the necessary
steps involved for your specific
application.
96448 v.12.0
7
Overview of Installation
**For help on how to identify what power
rating your engine is, see Section 6
8
96448 v.12.0
SECTION 1
Six-Gun Diesel Tuner Installation
For 2003 vehicles, start from Step 1.
For 2004 vehicles, start from Step 2.
1. FOR 2003 VEHICLES ONLY: Locate
the large black connector (C130) on
the driver side between the battery
and the firewall. See Figure 1. Remove
the two (2) plastic screws on the
sides of the connector and move the
connector aside. Retain the two (2)
screws and the two (2) retainers for
re-installation.
2. Locate the rubber grommet on the
drivers side firewall. Using a utility
knife, make a 1.5-inch-long slit in the
grommet next to the wire harness.
Be careful not to cut or damage
the harness. See Figure 2 for the
proper location of the required cut.
Insert a screwdriver from the engine
compartment into the cut hole and
thrust it through the grommet.
3. Inside the vehicle, remove the
lower dash panel beneath the steering
column by removing the two (2)
screws at the bottom of the panel.
Retain the screws for re-installation.
Figure 1
Figure 2
96448 v.12.0
9
NOTE: There are also two (2) clips
located at the top corners of the panel,
which hold the panel in place. These
clips can be released by gently pulling
on the corners of the panel. Use caution
to avoid damaging the panel during
removal.
4. Remove the electrical connector
bracket on the left hand side of the
support below the steering column in
front of the firewall by removing the
two (2) bolts. This will allow access to
the inner grommet. See Figure 3.
5. Cut the grommet on the firewall
inside the vehicle along the hole
created by the screwdriver in Step 2.
6. Locate the Six-Gun Diesel Tuner
wire harness end with the 8 and
10-pin connector. From the engine
compartment, push this end through
the hole cut in the grommet through
the firewall.
NOTE: Taping the end of the harness
to a piece of stiff wire (i.e. coat hanger)
may make routing the harness through
the firewall a simpler task. The stiff wire
should be pushed through the slit in
the grommet and then the wires can
be attached to the stiff wire and pulled
through the hole in the firewall.
Figure 3
10
96448 v.12.0
CAUTION: Pull gently to avoid
damage to the wire harness
connectors. Always pull on the
wire harness convolute sheath
rather than the wires themselves.
7. From inside the vehicle, continue
to pull the harness through the
firewall until the main harness is
approximately 22” inside the cab.
8. FOR AUTOMATIC TRANSMISSION
VEHICLES ONLY: Insert the end of the
provided TCC wire harness with the
4-pin connector through the grommet
from the engine compartment side
using the same hole. Pull the TCC
wire harness from inside the cab until
approximately 22” of the wire is inside.
Note: The TCC wire harness is not
applicable on vehicle with a manual
transmission.
9. In the engine compartment, locate
the CAN BUS connector on the drivers
side of the engine. It is a flat 3-pin
connector located on top of the fuel
lift pump below the MAP sensor next
to the ECM. Remove the weather seal
plug and insert the Six-Gun Diesel
Tuner CAN BUS connector into this
connector. See Figure 4.
Figure 4
Figure 5
96448 v.12.0
11
10. Find the Fuel Rail Pressure (FRP)
sensor on the fuel rail. It is located on
the drivers side of the engine. Unplug
the factory connector and plug it into
the Six-Gun harness. Plug the Six-Gun
FRP connector into the sensor. See
Figure 5.
11. Locate the Manifold Pressure
(MAP) sensor on top of the intake
manifold. Unplug the factory connector
and plug it into the Six-Gun harness.
Plug the Six-Gun MAP connector into
the sensor. See Figure 5.
CAUTION: The camshaft position
sensor and the crankshaft position
sensor have the same type of
connectors and they are in close
proximity to one another. Make
sure the right connectors are used
when installing these connections.
Refer to Figure 6 for their locations
on the Six-Gun Diesel Tuner wire
harness.
Figure 6
12
96448 v.12.0
12. Find the Crankshaft Position
(CKP) sensor on the lower front left
side of the engine. It is behind the
engine crankshaft pulley (engine
harmonic balancer). Unplug the
factory connector and plug it into the
corresponding CKP sensor connector
on the Six-Gun harness. Plug the SixGun CKP sensor connector into the
sensor. Take care to route the wire
harness away from the power steering
pump and secure it with the supplied
cable ties. See Figure 7.
13. Locate the Camshaft Position
(CMP) sensor below the fuel injection
pump between the timing gear
cover and the ECM. Unplug the
factory connector and plug it into the
corresponding CMP sensor connector
on the Six-Gun harness. Plug the SixGun CMP sensor connector into the
sensor. See Figure 8.
Figure 7
Figure 8
96448 v.12.0
13
Caution: It is very important that
you select the proper wire. The
Banks Six-Gun Diesel Tuner will
not function properly if installed
incorrectly.
For 2003 automatic transmission
vehicles, follow Steps 14 through
17. For 2003 vehicles with a manual
transmission, skip to Step 17.
For 2004 vehicles with an automatic
transmission, follow Steps 18
through 20. For 2004 vehicles with a
manual transmission, skip to Step 21.
14. FOR 2003 AUTOMATIC
TRANSMISSION VEHICLES ONLY: Route
the GRAY Banks TCC monitor wire
along the top of the firewall toward
the PCM on the passenger side. Undo
the clips (10 locations) and lay the
GRAY wire next to the factory wires.
Figure 9
14
96448 v.12.0
See Figure 9. Use a cable tie to secure
the TCC wire at the outlet.
15. Locate the three (3) PCM
connectors on the passenger side. On
the middle connector (usually white),
find the orange wire with black stripe.
Remove electrical tape on the factory
harness if necessary and install a
T-tap. Plug the GRAY TCC wire into
it. See Figure 10. Re-install the clips
along the top of the firewall.
NOTE: Disconnecting the PCM
connection might make the task easier.
16. Locate the solid RED wire in
the wire loom entering the C130
connector. This is the same connector
removed in Step 1. Install a T-tap on
the RED wire and plug the BLUE TCC
wire into it. See Figure 11.
Figure 10
Figure 11
96448 v.12.0
15
Figure 12
Figure 13A
16
96448 v.12.0
17. FOR ALL 2003 VEHICLES ONLY:
Locate the LIGHT GREEN wire with
black stripe in the wire loom entering
the C130 connector. This is the same
connector removed in Step 1. Install
a T-tap on this wire. Plug the red SixGun Diesel Tuner wire into this T-tap.
Tie the excess red wire to the wire
harness using the supplied cable ties.
Skip to Step 22.
18. FOR 2004 AUTOMATIC
TRANSMISSION VEHICLES ONLY: Plug
the TCC extension into the BLUE
TCC wire. Using the wire harness on
the two (2) connectors next to the
main brake cylinder as a guide (see
Figure 12), route the BLUE and gray
TCC wires toward the transmission
solenoid assembly that is sitting on the
transmission. It is located underneath
the drivers side of the vehicle. See
Figure 13A. Secure the wire using
cable ties along the way.
19. Find the yellow wire with
orange stripe on the solenoid
assembly. (There is a yellow wire
with a PINK stripe next to the yellow
wire with ORANGE stripe and it
may appear as a YELLOW wire with
ORANGE stripe. DO NOT T-tap this
YELLOW WIRE with PINK stripe!) Refer
to Figure 13B for the correct YELLOW
wire with ORANGE stripe pin number
and location. It is at pin #1. Apply
a generous amount of the supplied
dielectric grease into a T-tap and
install it on the YELLOW wire with
ORANGE stripe. Insert the blue TCC
wire into this T-tap. See Figure 13C.­
20. Find the yellow wire with light
blue stripe. Apply a generous amount
of the supplied dielectric grease into a
T-tap and install it on this wire. Insert
the gray TCC wire into this T-tap. See
Figure 13C.­
Figure 13B
96448 v.12.0
17
Figure 13C
Figure 14
18
96448 v.12.0
21. FOR ALL 2004 VEHICLES
ONLY: Locate the two (2) electrical
connectors next to the main brake
cylinder. Find the pink wire with gray
stripe on the connector closest to the
brake cylinder. Install a T-tap on this
wire. Plug the Six-Gun Diesel Tuner red
wire into the T-tap. See Figure 14.
22. Inside the cab, plug the main
8- and 10-pin connectors from the
wire loom into the front of the SixGun Diesel Tuner box. On vehicles
with automatic transmissions, plug
the 4-pin TCC wire harness connector
into the rear of the Six-Gun Diesel
Tuner box.
23. In the engine compartment,
unbolt the nut from the ground (-)
terminal on the drivers side battery.
Locate the ring terminal on the Six-Gun
Diesel Tuner wire harness. Install this
ring terminal onto the battery ground
and re-install the nut. See Figure 15.
24. FOR ALL 2003 VEHICLES ONLY:
Reinstall the large black connector
(C130) that was removed in Step 1.
Note: Go over the entire installation as
a precautionary check to ensure that all
clamps are tight, wiring and hoses are
properly routed, and connections are
correct and tight. Make sure that the
wire harness is not lying in the way of
the brake and gas pedals.
-end, section 1-
Figure 15
96448 v.12.0
19
SECTION 2
Installation of the Six-Gun POWER LEVEL Selector SWITCH
CAUTION: Do not use force
when working on plastic parts.
Permanent damage to the part
might result.
1. The Six-Gun switch will be installed
on the drivers side of the instrument
panel (IP) next to the steering column.
See Figure 16.
2. Remove the headlamp switch bezel
on the drivers side by gently pulling on
it. Disconnect the electrical connector
once the bezel is removed.
3. To remove the center bezel, open
the ashtray and cup holder and
remove the retaining screw. Gently
pull on the center bezel to disengage
all the clips that attach the bezel
to the dash. Disconnect the four
(4) electrical connections after the
bezel is removed. Keep the screw for
reinstallation.
4. Remove the cluster bezel by first
removing the two (2) screws at the
top. Gently pull on it and disengage
all the clips that attach the bezel
to the dash. Retain the screws for
reinstallation.
5. Cut out the supplied template (see
template. Remove and discard the
template and any plastic shavings.
NOTE: It is important that the hole is
drilled at the recommended location.
The switch may not clear the instrument
panel structure if the hole is shifted to
another location.
7. Align the Banks Six-Gun label onto
the previously drilled hole. 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 dampened with
rubbing alcohol or similar cleaning
solution.
CAUTION: Do not spray fluid
directly onto any electrical
equipment, or equipment damage
may result.
Mount the Six-Gun Diesel Tuner
switch label onto the cluster by
peeling the protective backing off
the adhesive tape on the back of the
switch label. Hold the label against the
panel for approximately 20 seconds
while applying pressure to allow the
adhesive to properly adhere to the
surface.
Figure 17 on page 33) and align the
template onto the front of the cluster
bezel by placing its left edge against
the cluster rib, and its bottom edge
against the cluster bottom edge. Use
masking tape to securely hold down
the template.
8. Remove the nut and internal tooth
NOTE: Do not tape over the markings on
the template.
NOTE: If the washer is in any position
other than the #6, your Six-Gun Diesel
Tuner will not select power levels
correctly.
6. Using a 3⁄ 8” Uni-drill, center the
bit onto the 3⁄ 8” drill location on the
template and slowly drill through the
IP. Using a 1⁄ 8” drill bit, center and
drill through the 1⁄ 8” location on the
20
96448 v.12.0
washer from the Six-Gun switch.
Rotate the shaft counter clockwise
until the shaft stops. Verify that the
locating washer tab is inserted into the
#6 position on the switch (see Figure
18).
Figure 16
Figure 18
96448 v.12.0
21
9. After confirming the locating
washer is in the #6 location, install the
switch through the 3⁄ 8” hole on the
backside of the bezel. The alignment
pin should rest in the 1⁄ 8” hole and
with the switch fully rotated counter
clockwise; the shaft’s flat side should
be facing the steering column. Secure
switch with internal tooth washer and
nut. Snug the nut. Be careful not to
over torque the nut and damage the
plastic threads.
10. Install the knob onto 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.
11. Reinstall the cluster bezel by
pressing on it to ensure all the clips
are engaged. Secure it with the
original two (2) screws.
22
96448 v.12.0
12. Reconnect the electrical
connector to the headlamp switch
bezel. Reinstall this bezel by gently
pushing on it until all clips are
engaged.
13. Reconnect the four (4) electrical
connections to the center bezel.
Reinstall this bezel by pushing on it to
engage all the clips. Open the ashtray
and cup holder and reinstall the
original screw.
14. Route the Six-Gun switch wires
down to the steering column.
15. Remove the 2-pin jumper from
the Six-Gun Diesel Tuner wire harness.
Connect this Six-Gun harness to the
2-pin connector on the switch wire.
-end, section 2-
SECTION 3
OPTIONAL THERMOCOUPLE INSTALLATION
If the thermocouple is not being installed,
skip to Section 4, TRANSMISSION
LEARNING PROCEDURE on page 25.
NOTE: The thermocouple is not required
to operate the Six-Gun.
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
outlet of the manifold adjacent to the
turbine housing. For this reason it is
essential that the turbocharger be
removed from the engine in order to
clean out any metal chips from drilling
that could cause turbine blade damage.
The Cummins ISB engine uses a divided
exhaust manifold. The thermocouple
may be installed to sample exhaust
temperature in either exhaust passage.
We recommend the rear passage
(toward the firewall).
2. Loosen the clamps that attach the
air inlet tube to the air filter housing
and to the turbocharger, and remove
the air inlet tube from the vehicle.
Remove the air filter housing from the
vehicle. This will allow easier access to
the turbocharger.
3. Loosen the upper hose clamp on the
turbocharger oil drain-tube hose that
is located between the two sections of
the oil drain tube.
4. Disconnect the oil supply hose
at the turbocharger. Disconnect the
compressor outlet hose that goes to
the intercooler.
5. Remove the turbine outlet pipe by
loosening the V-band. Save V-band for
re-installation.
sure the surface is clean and dry.
CAUTION: Anytime the turbocharger
is removed from the engine,
take care that no foreign objects
enter any of the turbocharger
connections on the engine or the
turbocharger. Foreign objects
entering air, exhaust, or oil
connections may cause major
damage to the engine and/or
turbocharger and is not covered
under any warranty. Cover the
open end of the intercooler pipe
with a clean rag, as this pipe is very
suscep-tible to foreign object entry.
7. Stuff clean shop towels into the
compressor outlet and inlet hoses to
prevent contamination from entering
the pipes. Cover the turbo oil drain pipe
to avoid contamination.
8. Stuff a small clean shop towel
or rag 4 to 5 inches into the rear
exhaust manifold passage through the
turbocharger mounting flange. This
is to prevent chips from entering the
manifold while drilling and tapping.
9. Use a 7⁄16” drill, keeping the drill
perpendicular to the manifold surface
and drill through the exhaust manifold
into the rear passage as shown in
Figure 19.
10. Tap the drilled hole with a 1⁄4” NPT
pipe tap. 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.
6. Remove the turbocharger mounting
nuts/bolts and the turbocharger from
the exhaust manifold. Clean and
inspect the exhaust flange mounting
surfaces on the exhaust manifold. Make
96448 v.12.0
23
Figure 19
11. Remove all loose chips from the
exhaust manifold. A shop vacuum or
small brush will help. Now remove the
rag using a welding rod or coat hanger
bent into a hook.
Caution! Make sure rags are
removed from exhaust manifold
prior to reinstalling turbocharger!
12. Install the thermocouple in the
manifold using anti-seize on the
threads.
13. Attach the thermocouple to
the supplied thermocouple leadwire
extension with supplied nuts and bolts.
Connect the yellow and red wires
of the leadwire to the corresponding
ring terminals on the thermocouple.
Cover this joint with the supplied heat
shrink tubing and heat until the tubing
conforms to the joint. Make sure the
entire joint is insulated. Route the
thermocouple leadwire through the
grommet in the firewall. Plug the 2-pin
leadwire connector into the front of
the Six-Gun Diesel Tuner inside the
vehicle cab.
24
96448 v.12.0
CAUTION: Remove all the rags that
are inside the compressor hoses
and the exhaust manifold before
re-installing the turbocharger.
14. Install the new turbine inlet gasket
provided and apply a dab of anti-seize
compound to the four turbo mounting
studs. Install the turbocharger on the
exhaust manifold. As the turbocharger
is reinstalled, slip the oil drain tube
into the drain hose. Tighten the
turbocharger mounting nuts to 24
ft-lbs. Tighten the oil drain hose clamp.
15. Reconnect and tighten the turbo
oil supply hose.
16. Reconnect the turbine outlet pipe
to the turbocharger and secure it with
the V-band.
17. Re-install the air filter housing that
was previously removed.
-end, section 3-
SECTION 4
Transmission learning procedure
Your Six-Gun Diesel Tuner displays
the “4,3” diagnostic code (refer to
TROUBLESHOOTING in Section 9 on
how to read codes) when it needs to
learn your transmission configurations.
This always occurs when the Six-Gun
Diesel Tuner is first installed on the
truck.
3. If a Speed-Loader is being installed,
Banks Six-Gun Diesel Tuner is equipped
with advanced safety features to
preserve your automatic transmission.
One of them is the capability to detect
the occurrence of transmission slip,
and it will automatically de-rate the
engine output power accordingly.
Before this safety feature can take
effect, the Six-Gun Diesel Tuner needs
to learn that your truck is equipped
with an automatic transmission.
(Please read the “Disclaimer of
Liability” on page 4.)
4. To teach the Six-Gun Diesel Tuner
1. Reconnect all battery terminals.
The following driving test shall be
performed in an area where speeds of
this nature are safe and traffic is light.
For vehicle with a manual transmission,
follow Steps 2 through 3. For vehicle
with automatic transmission, follow
Steps 4 through 6.
While driving, listen for any exhaust
leaks or rattles, or intake boost leaks.
After the engine cools, re-tighten
clamps and hoses if leaks are
detected.
2. To teach the Six-Gun Diesel Tuner
that your truck is equipped with a
manual transmission, drive the truck at
a vehicle speed of over 50 mph for at
least 2 minutes. The “4,3” diagnostic
code will be eliminated.
go to Section 5, “SPEED-LOADER
MODULE INSTALLATION” on page 26
and follow the procedure; otherwise
proceed to Section 6, “ENGINE POWER
RATING LEARNING PROCEDURE” on
page 27. Repeat Step 2 if necessary
to eliminate code.
that your truck is equipped with an
automatic transmission, drive your
truck under light load with overdrive
turned on (4th gear). Obtain a vehicle
speed of over 60 mph until torque
converter is locked (the torque
converter is usually locked at speeds
over 60 mph). Maintain this speed
steadily with the torque converter
locked for at least 30 seconds.
5. Continue to drive. Slow down and
turn off overdrive and obtain vehicle
speed of over 50 mph until torque
converter is locked (with overdrive
off the torque converter is usually
locked at speeds over 50 mph).
Maintain the speed steadily with the
torque converter locked for at least 30
seconds.
6. Once the transmission is learned,
the “4,3” diagnostic code will be
eliminated. If a Speed-Loader is being
installed, go to Section 5, “SPEEDLOADER MODULE INSTALLATION” on
page 26 and follow the procedure,
otherwise proceed to Section 6,
“LEARNING ENGINE POWER RATING”
on page 27. If the code is not
eliminated, repeat Steps 4 to 5.
-end, section 4-
96448 v.12.0
25
LEFT INTENTIONALLY BLANK
26
96448 v.12.0
SECTION 5
Engine Power Rating learning Procedure
To be performed on part number
62977 only. If installing part number
62979, skip to section 7 on page 29.
Your Six-Gun Diesel Tuner (with or
without the Speed Loader) needs to
know the correct power rating of your
engine in order to provide the proper
calibration and tuning. The correct
engine power rating can be found on
the tag in the engine compartment at
one of the locations shown in Figure
20. The power rating is typically shown
in the upper right hand corner of the
tag. The rated power should be 235,
250 or 305 hp. If the rating is different,
contact Gale Banks Technical Support.
Follow the steps described below
(Step 1 to 6) to teach your Six-Gun
Diesel Tuner the power rating of your
engine. As shipped, the Six-Gun Diesel
Tuner is calibrated for a 305 hp (High
Output) engine. If you have a 305
hp rated engine, skip to Section 7,
“CHECKING ENGINE PERFORMANCE”
on page 29.
1. If you have a 235 hp or 250
hp rated engine, remove the
thermocouple leadwire from the SixGun Diesel Tuner box connection.
Insert the provided engine rating
jumper key into the Six-Gun Diesel
Tuner box thermocouple connection.
See Figure 21.
2. Turn the key to ON position (DO
NOT start engine) and wait 5 seconds.
3. Turn the key to OFF position, wait
5 seconds and turn the key to ON
position (DO NOT start engine) and
wait 5 seconds.
4. Again, turn the key to OFF position,
wait 5 seconds and turn the key to ON
position (DO NOT START ENGINE) and
wait 5 seconds.
5. When the procedure is completed
correctly, the Six-Gun Diesel Tuner will
flash the red LED once.
Figure 20
96448 v.12.0
27
6. Turn the key to the OFF position
and remove the engine rating jumper
key. Re-install the thermocouple
leadwire into the Six-Gun Diesel
Tuner box.­
Note: Each time the key is turned
on, the Six-Gun Diesel Tuner will flash
the red LED once at power up to
indicate that it has been calibrated as a
235hp/250 hp engine rating.
A 305 hp rated engine calibration
does not flash a red LED. If you have
incorrectly used a 235 hp/250 hp
calibration on a 305 hp rated engine,
excessive fuel rail pressure will result
and the Six-Gun Diesel Tuner will
automatically adjust the calibration to
the 305 hp rated engine level and the
Figure 21
28
96448 v.12.0
red LED will not flash at power up. A
“4,4” diagnostic code will be generated
and stored in the Six-Gun Diesel Tuner
in the process. A ”4,4” will also be
generated and stored in the Six-Gun
Diesel Tuner on a 235 hp or 250 hp rated
engine if excessive fuel rail pressure is
detected. This “4,4” code is eliminated
and cleared when the key is turned off
and turned back on.
If “4,4” diagnostic code keeps being
generated and stored on your SixGun Diesel Tuner, contact Gale Banks
Engineering Technical Support.
-end, section 5-
SECTION 6
CHECKING ENGINE PERFORMANCE
Note: The Six-Gun Diesel Tuner requires
the engine coolant temperature (ECT) to
be above 125º before it will add fuel.
Note: This verification of proper
performance should be performed prior
to permanent mounting of the Six-Gun
Diesel Tuner as illustrated in Section 8.
If DynaFact® gauges are installed,
observe the operation of the boost and
pyrometer gauges while driving under
varying conditions. Turbocharger boost
pressure will increase as a function of
load and engine RPM, thus the engine
will produce little boost while cruising
at light throttle, with maximum boost
while climbing hills heavily loaded
during acceleration.
Note: The boost level seen during
hard acceleration with a given load. If
performance seems to have deteriorated
sometime in the future, the maximum
boost figures may be compared to see
if boost has dropped off. Lower boost
may be caused by turbo ducting leaks,
a malfunctioning wastegate or fuel
injection pump, or dirty air filter. Typical
maximum boost pressure settings for
the Dodge/Cummins diesel will vary
considerably with stick or automatic
transmission options, year model of
vehicle and altitude.
Note: Before key-off, check tuner for
error codes.
Use your pyrometer gauge to
monitor exhaust gas temperature
(EGT) in the engine. At idle, exhaust
gas temperature will be very low,
perhaps only 300°F. As the engine
is accelerated for higher speeds
with greater loads, the EGT will rise.
The highest EGT will be seen under
maximum load at full throttle, such as
climbing a steep grade with a heavily
laden vehicle. Your pyrometer is color
coded to assist in your reading of
the gauge. The red zone indicates a
dangerous level of temperature. Your
engine should not operate in this
range for more than a few seconds.
The blue zone indicates when it is safe
to shut the engine off. To avoid heat
damage to various engine components
it is recommended that the exhaust
gases cool below 400º before the
engine is shut down.
Your Six-Gun Diesel Tuner is calibrated
to maintain a maximum EGT of
1350°F. You may experience brief
excursions slightly above 1350°F under
acceleration. This is normal and EGT
should return to 1350°F or below
within a few seconds. If you find that
EGT remains high for any length of
time, check for boost leaks or a dirty
air filter.
-end, section 6-
96448 v.12.0
29
SECTION 7
Mounting the six-gun module
1. After confirming the functionality
of the system, make sure the entire
mounting surface is clean and free of
dirt and oil before mounting the SixGun Diesel Tuner. Clean and dry as
required using a cloth dampened with
rubbing alcohol or similar cleaning
solution.
CAUTION: Do not spray fluid
directly onto any electrical
equipment, or equipment damage
may result.
Mount the Six-Gun Diesel Tuner on
the back of the lower dash panel as
shown in Figure 22 by peeling off the
protective backing off the adhesive tape
on the back of the Six-Gun Diesel Tuner
box.
Note: The Six-Gun Diesel Tuner may
not clear the steering structure if it is
mounted differently.
Figure 22
30
96448 v.12.0
2. Hold the module against the
panel for approximately 1 minute
while applying pressure to allow the
adhesive to properly adhere to the
surface.
3. Re-install the electric connector
bracket that was removed in Step 4
below the steering column in the front
of the fire wall with the original two (2)
bolts.
4. Route all wiring away from any
pedals or other moving components.
Using the cable ties supplied, secure
the wiring under the dash. Secure all
wiring under the hood away from heat
sources or sharp edges. Re-install the
lower dash panel with the original 2
bolts. Your Banks product installation
is complete.
-end, section 7-
SECTION 8
TROUBLESHOOTING
Note: The Six-Gun Diesel Tuner requires
the engine coolant temperature (ECT) to
be above 125º before it will add fuel.
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 vehicle
key to ON position. Observe the two
LEDs mounted on the upper corners
of the black connector on the end of
the Six-Gun Diesel Tuner. If all wire
connections are correct, a steady
green light is illuminated. If the green
light is not illuminated when key is
on, check power supply hookup and
the fuse on the Six-Gun main wire
harness. If connection and fuse are
okay, contact Banks Technical Service.
If a connection is incorrect or if there
is a problem with the system, when
the key is on 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 in
between. 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.
(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
by 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.
Note: The “4,3” code comes on when
the Six-Gun Diesel Tuner module is first
installed on a vehicle. To eliminate this
code, follow the instructions described in
the “LEARNING TRANSMISSION” section.
If problem persists, contact Banks
Technical Service.
If the Six-Gun Diesel Tuner should ever
need to be removed from the vehicle,
the system includes a by-pass plug
that must be connected to the white
8-pin connector (next to the 10-pin
connector) on the Banks wire harness.
Failure to utilize the by-pass plug will
result in a “Check Engine” light on the
dash and a Diagnostic Trouble Code
being stored in the factory computer
and the engine will not start.
-end, section 8-
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:
96448 v.12.0
31
Table 1: Banks Six-Gun Diagnostic Codes
Diagnostic Code Description
Course of Action
Code
1,1
Faulty Fuel Rail
Pressure (FRP) input
signal
Check FRP sensor connection and 8-pin Six un Diesel Tuner connector. Reset Six-Gun
G
Diesel Tuner by turning key on and off.
1,2
Faulty Manifold
Absolute Pressure
(MAP) input signal
heck MAP sensor connection and 8-pin SixC
Gun Diesel Tuner connector. Reset Six-Gun
Diesel Tuner by turning key on and off.
1,3
Faulty Six-Gun signal
input
Make sure the Six-Gun switch is connected to
the main wire harness. Reset Six-Gun Diesel
Tuner by turning key on and off.
2,1
Faulty Fuel Rail
Check FRP sensor connection and 8-pin SixPressure (FRP) output Gun Diesel Tuner connector. Reset Six-Gun
signal
Diesel Tuner by turning key on and off.
2,2
Faulty Manifold
Absolute Pressure
(MAP) output signal
heck MAP sensor connection and 8-pin SixC
Gun Diesel Tuner connector. Reset Six-Gun
Diesel Tuner by turning key on and off.
2,3
aulty thermocouple
F
signal
TCC stuck (automatic
transmission ONLY)
Check thermocouple connection and 2-pin
Six-Gun Diesel Tuner connector.
Check TCC connection and 4-pin Six-Gun
Diesel Tuner connector. Monitor code
occurrence. Contact Banks Technical Service
if occurrence becomes frequent.
Check both the CKP and CMP sensor
connections and 8-pin Six-Gun Diesel Tuner
connector. Reset Six-Gun Diesel Tuner by
turning key on and off.
2,4
3,1
Faulty Crankshaft
Position (CKP) or
Camshaft Position
(CMP) signal
3,2
Internal module error Contact Banks Technical Service.
3,3
Internal module error Contact Banks Technical Service.
3,4
Faulty CAN bus signal Check CAN bus connection and 10-pin Six-Gun
Diesel Tuner connector.
Transmission slip
Six-Gun Diesel Tuner will automatically derate
detected
engine power to preserve the transmission.
(automatic
transmission ONLY)
Transmission
Follow the instructions described in “Learning
learning has not been Transmission”section of the Owner’s Manual.
completed
See Section 4 on page 25.
4,2
4,3
4,4
Fuel rail pressure is
excessive
RP exceeded maximum allowable. Verify
F
engine power rating and perform Section 6 on page 27 again.
Contact Banks Technical Service if problem persists.
32
96448 v.12.0
SECTION 9
CLEARING learned transmission procedure
NOTE: This procedure should only be
performed if:
B1. Turn the vehicle key to the ON
position but DO NOT start engine.
(a) A ”4,2” code for transmission slip
detection is repeatedly set or will
not clear and the transmission is not
actually slipping; or
B2. Fully depress the throttle pedal
and then release it completely. Repeat
for 5 times. The green LED will flash
when this is completed successfully.
(b) The Six-Gun Diesel Tuner is moved
to a new vehicle; or
B3. Turn key off. Wait 10 seconds or
until the green LED goes off and stays
off. Turn key to on position but do not
start engine.
(c) The speedometer has been
recalibrated for different gearing or tire
size; or
(d) Instructed to do so by Banks
Technical Staff.
Your Six-Gun Diesel Tuner also has
the capability to clear the information
related to the learned transmission
type and gear ratios. The diagnostic
code “4,3” will reappear after the
procedures are carried out correctly.
Follow the steps below to unlearn the
transmission on your Six-Gun Diesel
Tuner.
CAUTION: The following procedures
can only be carried out with the
engine off.
B4. Fully depress the throttle pedal
and then release it completely. Repeat
for 5 times. The “4,3” diagnostic code
will display when this is completed
successfully.
NOTE: When the transmission type and
gear ratios are cleared (with code “4,3”
displayed), the engine power returns and
remains in stock level until the Six-Gun
Diesel Tuner re-learns the transmission
and code “4,3” is eliminated. Follow the
procedures in Section 4’s LEARNING
TRANSMISSION to eliminate code “4,3”.
-end, section 9-
Figure 17
96448 v.12.0
33
NOTES
34
96448 v.12.0
NOTES
96448 v.12.0
35
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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