Banks 42747 Big Hoss Owner's Manual

Manual is about: Intake Manifold System for Dodge Cummins 2003-2007 (235, 250, 305 and 325 HP)

Summary of 42747 Big Hoss

  • Page 1

    Banks big hoss ® intake manifold system 2003-2007 (235, 250, 305 and 325 hp) dodge cummins 5.9l (24-valve) isb pickup trucks this manual is for use with kits 42747 owner’s manual with installation instructions.

  • Page 2

    Banks iq system (p/n 61148-61149) - 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, 4...

  • Page 3

    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 banks diesel tuner economind w/switch (p/n 63725, 63793, 63795, 64507) economind w/iq (p/n 63807, 63808, 63817, 63818)...

  • Page 4: Section 2

    4 96774 v.5.0 table of contents section 1 . . . . . . . . . . . . . . . . 4 system description section 2 . . . . . . . . . . . . . . . . 4 cylinder head preparation section 3 . . . . . . . . . . . . . . . . 5 bandsaw rough cut section 4 . . . . . . . . . . . . . . . . 6 machining manifold face secti...

  • Page 5: Section 3

    96774 v.5.0 5 all position references for bandsawing and machining are measured from the front cylinder headbolt dowel hole (right front hole) next to the thermostat pocket. Viewing the head from above, locate this hole and the row of head bolts down the right side of the head. (7 total) from the ce...

  • Page 6: Section 4

    6 96774 v.5.0 turn the cylinder head over so the head gasket surface faces up. Once again locate the front head bolt dowel hole and corresponding row of seven head bolt holes. From an accurate location of the centerline of this row of head bolt holes, measure and scribe a reference line the length o...

  • Page 7

    96774 v.5.0 7 figure 3.

  • Page 8: Section 6

    8 96774 v.5.0 the layout for the drilled and tapped holes on the machined intake face is referenced from the centerline of the front head bolt and the head gasket surface of the head. Figure 3 shows the locations of the upper and lower bolt hole rows, as well as the three (3) dowel pin holes. Import...

  • Page 9

    96774 v.5.0 9 figure 4.

  • Page 10: Section 7

    10 96774 v.5.0 1. If not previously installed, tap the three (3) 3 ⁄ 16 x 3 ⁄ 8 dowel pins into holes on the cylinder head intake flange face. Dowel pins must not protrude more than .200 inch from the milled surface of the head. 2. Install the o-ring into the groove on the intake manifold. Remove an...

  • Page 11

    96774 v.5.0 11 plastic fastener where the clip nut was installed. 15. Bend dipstick tube as required allowing dipstick tube bracket to be fastened to the clip nut on the throttle controller with an m6 x 50mm hex bolt and 1-inch long spacer. Install bolt with m6 split lock washer and 1 ⁄ 4 sae washer...

  • Page 12

    12 96774 v.5.0 dipstick tube - 20 x 1 hex bolt 1 __ 4 1 __ 4 1 __ 4 1 __ 4 3 __ 8 1 __ 4 split lock washer sae washer sae washer 5 - inch hex link x 1 link assembly 1 __ 4 stud figure 7 1 __ 4 3 __ 4 - 20 x 12 point bolt link assembly figure 8.

  • Page 13: Bill Of Materials

    Bill of materials item part no. Qty. Description 1 42748 1 intake manifold 2 41315-09 2 tab-boost tube 3 90040 1 sealant, ptfe paster 4 92780 4 rod end bearing, 1 ⁄ 4 - 28 r.H. Male shank x 1 ⁄ 4 dia. Hole. 5 92898 2 hose clamp, t-bolt, 4.00 to 4.50 dia. Range, stainless 6 93820 1 o-ring, 3 ⁄ 32 x 2...