4. One of the first steps, and certainly the easiest, is installing the Banks Ram-Air filter element. Banks engineers feel this modification is all that is needed for the stock air box to flow enough air. Remember, just upstream, we will be installing a modified turbo compressor impeller capable of drawing much more air through the filter and air box.4. One of the first steps, and certainly the easiest, is installing the Banks Ram-Air filt 5. Whitney goes after the intercooler, which is buried under the core support and is quite a task to get to. After removing the grille and lots of plastic air ducting, the top of the core support can be unbolted and removed, as shown here. This exposes the intercooler and allows its removal.5. Whitney goes after the intercooler, which is buried under the core support and is quite 6. Next, all the factory air ducting is removed from the inlet and outlet sides of the intercooler. These tubes are replaced with mandrel-bent pieces that feature 45- degree, instead of 90-degree, bends. This allows for freer flow of intake air.6. Next, all the factory air ducting is removed from the inlet and outlet sides of the int 7. With the stock intercooler removed from the truck, a comparison to the Banks Techni-Cooler (in the foreground) is possible. Note the larger intake and much broader ramp angles leading to the cooler core. The stock inlet directs air to just the center of the cooler, causing turbulence, restriction, and less-efficient cooling.7. With the stock intercooler removed from the truck, a comparison to the Banks Techni-Coo 8. After the new intercooler was installed, Whitney turned his attention to removing the intake manifold, allowing access to the turbo assembly. Here the manifold has been removed and you can finally see the turbo assembly tucked in under the cowl. Whitney then removes the turbo.8. After the new intercooler was installed, Whitney turned his attention to removing the i 9. On the bench, the compressor housing is split apart, exposing the compressor wheel, the driven side of the turbo. The wheel is the device that sucks incoming air through the air filter and rams it, under pressure, into the intercooler and on to the intake manifold and the cylinders. It is spun via the drive side of the turbo, which is powered by exhaust gases. We'll work on that side next.9. On the bench, the compressor housing is split apart, exposing the compressor wheel, th 10. Here is a close-up of the two compressor wheels. The stock one is on the right and the Banks one is on the left. Note the difference in the pitch of the blades, and that every other blade on the Banks unit is a different height. These changes allow the wheel to move more air for a given rpm. They also make Jane whistle like a big rig under acceleration, which sounds really cool. A note on noise: Overall, I've noticed very little change in the sound of the truck. Despite the much larger exhaust tubing and a flow-through muffler, the exhaust note seems no louder than stock, just a little more throaty. Other than the aforementioned whistle, the engine itself sounds no different.10. Here is a close-up of the two compressor wheels. The stock one is on the right and the 11. With the driven side of the turbo taken care of, we now flip the assembly over and disassemble the drive, or exhaust side. Here the wastegate is removed and set aside, allowing access to the turbine housing.11. With the driven side of the turbo taken care of, we now flip the assembly over and dis 12. The exhaust turbine housing is removed from the center bearing housing. Four bolts hold the two together. These bolts have a history of coming loose and destroying your turbo. Ford has issued a Technical Service Bulletin on this subject, but I was never notified of this problem. It's a good thing we tore Jane apart when we did, as one of these bolts was missing and the other three were loose.12. The exhaust turbine housing is removed from the center bearing housing. Four bolts hol 13. A comparison between the Banks and stock turbine housings doesn't reveal any differences. That's because all the differences are on the inside. The Banks housing has a larger inside diameter, which creates more room around the impeller, allowing more exhaust gas to fit into the turbine chamber. Since we've forced more air through the intake side and into the combustion chamber, when the exhaust valve opens, all that extra air wants out. The stock turbine housing is too small to handle this extra air and backpressure builds up, causing excessive exhaust gas temperature, which inhibits the power potential. With the bigger Banks housing, the air can pass quickly over the turbine blades, spin the turbo, then dump into the equally free-flowing 4-inch exhaust pipe for a trip to the back of the truck. 14. Before those exhaust gases completely escape down the exhaust pipe, they first pass by the wastegate. This unit acts like a trap door and stays closed unless pressure becomes too great within the turbine housing, or the engine is in warm-up mode and the computer doesn't allow it to receive a lot of boost. When this happens, the wastegate door is opened by the actuator on the left, allowing the exhaust to bypass the turbo and go straight down the tailpipe. The Banks Big Head actuator on the right replaces the stock unit. The Big Head is calibrated for the changes made in turbine pressure by the new turbine housing. It maintains more boost throughout the powerband while making sure there is no over-boost. 15. After all the mods were made to the turbocharger, it was reinstalled. Then Whitney tackled installing the new ducting, which runs from the new intercooler to the engine. These pieces are a tight fit.15. After all the mods were made to the turbocharger, it was reinstalled. Then Whitney tac 16. This close-up of a bend in the right-side air duct shows how the stock tube (on the top) makes a sharp 80-degree bend, creating turbulence and restriction. The Banks tube uses two 45-degree bends to achieve the same curve. This allows for smoother airflow, less pressure loss, and ultimately, more power.16. This close-up of a bend in the right-side air duct shows how the stock tube (on the to 17. With the installation of the air ducts completed, the underhood work is done. We now move under the truck. Here, the entire stock exhaust has been removed and laid out for comparison with the new Banks Monster tailpipe and Dynaflow muffler.17. With the installation of the air ducts completed, the underhood work is done. We now m « | 1 | 2 | 3 | » | View Full Article By Ned Bacon Enjoyed this Post? Subscribe to our RSS Feed, or use your favorite social media to recommend us to friends and colleagues!