Technical > Installation Guide
Banks' Big Hoss Install, Part 2
Installing the Monster Exhaust and Computer Module
story & photos by Steve Temple
In our previous issue, we showed how to install the intake and intercooler upgrades that are part of the Banks Big Hoss Bundle for diesel trucks. As you may recall, this performance package is good for as much as a whopping 50 percent gain in power. And that’s measured at the rear wheels, where it counts for climbing power and towing torque. It’s all done without any mods to the turbo system. The Six-Gun tuning module simply manipulates three basic engine parameters: fuel pressure, injector pulse width, and timing. Not only that, with the Speed Loader option, the total power increase can go as high as 58 percent.
To protect the engine, the Banks system monitors a number of variables with an AutoRate powertrain management system. Among other features, it provides lockup protection for the torque converter clutch, turbo calibration, precise fuel delivery at shift points, an exhaust-gas temperature limiter (in the Speed Loader option), and coolant monitoring. If there’s any indication that the engine is being overtaxed, Banks Six-Gun has a self-diagnosing ActiveSafety feature with an automatic bypass, which returns the engine to its standard settings.
To make the most of the Banks tuning module, the exhaust must be upgraded for a better flow. Also, a thermocouple is a necessary addition to ensure careful monitoring of exhaust-gas temperatures, since they will be higher as you dial up the output.
Speaking of output, we tested the Ford F-250 in the dirt after installing the Banks upgrades. Satisfied that this truck can kick up big clouds of dust, we decided to bait some sports cars on the freeway. We pulled up next to an Acura NSX that had been tricked-out with all sorts of tuner trash, and then promptly stomped on the loud pedal, and left ‘racer boy’ in our diesel exhaust. The pucker on his face was priceless. Who’d a thought a big diesel 4x4 could blow off a sports car? That’s one Big Hoss, brutha!
Buy Banks' Six Gun Bundle from www.4wheelparts.com.
Wrench Rating:
Because of the extensive electrical work to be done
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1. A thermocouple probe must be installed to accurately measure exhaust-gas temperatures. For that, a bung is first drilled and tapped into the left-side exhaust manifold. The exhaust manifold should be removed for this process to ensure that absolutely no metal shavings get into the turbocharger, which can cause serious damage. After drilling and tapping the exhaust manifold, thoroughly clean it with a high-pressure air hose to remove all traces of metal shavings before installing the probe. |
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2. Note the difference in size between Banks Monster Exhaust (top) and the factory exhaust head pipe. Monster Exhaust pipes have much higher flow due to a larger, more consistent diameter. Banks uses 4-inch constant-diameter, stainless-steel tubing, which is designed to last considerably longer than exhausts made from aluminized steel. |
3. The factory catalytic converter is the only part of the stock exhaust that is not replaced with the Banks Monster Exhaust pipes. After the head pipe is installed, the factory converter can be re-installed. |
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4. After fitting on the Banks Monster Muffler, the tailpipe and tip go on next. |
5. The Banks Six-Gun Diesel Tuner mounts under the hood on the driver’s side inner fender on 2003-2004 Ford 6.0-Liter Power Stroke Diesel models (consult Banks’s manual for info on mounting the Six-Gun on 2005 models). To clear a spot for the Six-Gun, a small clip must be removed which attaches the hood latch cable to the inner fender. After pushing the cable out of the way, the inner fender area should be cleaned with rubbing alcohol to ensure a good bond for the Six-Gun’s adhesive backing. |
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6. The Banks Six-Gun takes up very little room when mounted into position on the inner fender, and requires no mounting screws or bolts. |
7. In addition to the large connector that plugs into the Powertrain Control Module (PCM), there are several wires that must be spliced with “T-Taps” (included). Banks provides detailed wiring installation instructions in its Six-Gun Diesel Tuner Owner’s Manual. |
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8. Banks provides a template for locating its Six-Gun control switch knob on the Ford’s dashboard. |
9. The Speed-Loader increases the output of the Banks Six-Gun Diesel Tuner by 23 hp and 25 lb./ft. of torque. The Speed-Loader Upgrade also provides the important safety feature of limiting fuel delivery when the exhaust gas temperatures (EGTs) reach a preset temperature (1400 degrees Fahrenheit on the Ford 6.0-liter Power Stroke diesel). The unit is small and mounts in any convenient location under the dash near the Six-Gun control switch knob, and plugs inline into the wiring for the dash-mounted Six-Gun switch. |
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10. Thankfully, there are detailed wiring instructions to install Banks DynaFact electronic gauges are also in the Big Hoss Bundle. |
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