Ford Power Stroke Bulletproofing Tactics

Editor's note: Last month we showed you how to cure most of the common engine-related issues associated with the 6.0L Navistar International-built V-8. The mill can be found in a variety of diesel-powered Ford platforms, including Super Duty pickups, Econoline vans, and Excursion SUVs. Our coverage was tailored specifically for the heavy-duty pickups built between 2004 and 2007. This time we're going to demonstrate how much power you can expect to make with a series of proven modifications that do not compromise longevity. Installing performance- and durability-enhancing upgrades such as the Banks Big Hoss Bundle featured in this article can be a rewarding and fun endeavor. Naturally, you want to begin such a project with a sound and solid platform. The many recommendations featured in last month's issue coupled with the upgrades detailed here in Part 2 will not only result in a powerful, useful, and incredibly versatile machine, but also one on which you can depend for many years to come.

129 1010 Ford Power Stroke Bulletproofing Tactics Banks Big Hoss Bundle

This is the complete Banks Big Hoss Bundle for the Ford 6.0L. The system includes improvements in every aspect of intake, intercooler, and exhaust flow. It even comes with an adjustable power module that adds up to 138 horsepower and 231 lb-ft of torque without any additional smoke. The system includes a driver's interface, the Banks IQ, which is Windows CE-based. Think of it as a little dash-top PC that features a 5-inch touch screen and open platform flexibility. Virtually any Windows CE program you run on your home PC will work on the IQ. The biggest innovation with this setup is the Banks Speed Brake, but we will get into that a little later.

This is the complete Banks Big Hoss Bundle for the Ford 6.0L. The system includes improvem

Gale Banks knows diesel engines. Having been in the business for more than 52 years, his name is to the diesel industry what Vic Edelbrock's is to hot rods. And it didn't become that way by accident. Banks is a detail-oriented man, who stops at nothing to ensure that his products are innovative, reliable, and user-friendly. His electronics feature triple redundancy to ensure fail-safe operation, and his no-smoke approach to producing power is as forward thinking as you can get. We have been to his impressive manufacturing facility in Azusa, California, a handful of times and can attest to the high level of detail and thought he so proudly puts into his products. Above all, we felt Banks was the best possible fit for a 6.0L build because his power numbers are expertly metered to be safe and sustainable for an engine that is already pushing the limits of reliability in stock form. For this story, we spent three days at the Banks factory, including several hours with the legend himself. The experience was surreal and the results were impressive. Check it out.

129 1010 Ford Power Stroke Bulletproofing Tactics Factory And Banks Air Filter

Here you can see the differences between the factory air filter assembly and the improved Banks unit, which uses a cleanable dome-shaped cotton filter element instead of a one-and-done paper element filter. The new arrangement outflows the factory setup by 38 percent.

Here you can see the differences between the factory air filter assembly and the improved

Where 6.0L Power Stroke Inefficiencies Start
To harness additional power from a 6.0L engine, you must first understand where the OE design falls short. Think of an engine as a massive air pump. As fresh air passes through the stock filter, resistance rears its ugly head right from the start. The inlet to the filter housing features a small opening that inhibits airflow to decrease noise and the likelihood of water intrusion. The paper filter element resembles a four-pack of paper towels, like the kind you might find on the shelf at your local supermarket. Only these towels have been squeezed tightly together to increase surface area. While the OE element does a great job removing particulates from the air, it does so at a significant cost to efficiency-especially after several thousand miles of debris becomes trapped in the first few inches of its labyrinth-like design. After the filter, airflow makes an abrupt left turn, creating turbulence and further resistance. The result is a significant amount of suction restriction for the turbo to overcome to do its job. The effect is compounded by a 2-inch-diameter turbo boost discharge tube that has a section that is compressed even further to clear a part of the battery tray. Next, charged air passes through the factory intercooler, which features internal support partitions that interrupt flow. Can you see a pattern? Ultimately, the whole engine intake design is flawed if performance is a factor. The folks at Banks have addressed these issues and figured out a way to open up a window of efficiency for the 6.0L to capitalize on.

The Banks filter housing eliminates sharp bends and restrictions, allowing airflow to pass through the unit more freely. Additionally, the box features a removable access lid that makes filter changes a breeze.
The Banks filter housing eliminates sharp bends and restrictions, allowing airflow to pass
The intake ram is the final part of the intake setup before airflow is distributed to each cylinder bank via the intake manifold. The factory unit is small in comparison to the Banks High-Ram intake and slows airflow significantly. The Banks unit uses a 31/2-inch constant-diameter interior with contours that help reduce pressure loss as air passes through it.
The intake ram is the final part of the intake setup before airflow is distributed to each
To accommodate the larger High-Ram intake, a small portion of the factory fan shroud needed to be trimmed. The Banks technician did a clean job using a razor knife. The portion removed is more for looks than anything else.
To accommodate the larger High-Ram intake, a small portion of the factory fan shroud neede

The Banks Techni-Cooler replaces the factory unit and improves air density by up to 10 percent. More air density equals more oxygen for the combustion process. It achieves these improvements by increasing the interior volume by 21 percent and core surface area by 19 percent. As is the case with most heat exchangers, bigger is typically better, but there is a lot more to it than just size. The Banks unit also bests the OE design by utilizing cast aluminum side tanks that are welded directly to the core structure, unlike the factory tanks that are made from less-costly plastic that is held to the core structure by a row of folded tabs that can distort and cause leaks. The Banks design also features rounded contours that help smooth out laminar airflow both inside the tanks and on the outside, where air flows over the core structure.
The Banks Techni-Cooler replaces the factory unit and improves air density by up to 10 per
The intercooler's primary job is to cool the charged air prior to entering the combustion chamber. The result is more oxygenated air, which allows for more fuel to be transformed into power. A byproduct of this process is lower exhaust gas temperatures (EGTs)-a good thing. This is extremely important for pulling large mountain passes during towing scenarios. As engine load increases, operating temperatures also rise. As things get hot under the hood, heat is absorbed by all materials in the engine compartment. This effect is referred to as "heat soaking." The intercooler is a diesel engine's primary defense to heat soaking, and that's why an intercooler is so important. Gale Banks said it best when he told us, "A diesel engine is not complete without a turbocharger and an intercooler." And we think he's absolutely right.
The intercooler's primary job is to cool the charged air prior to entering the combustion
Other key factors to consider are boost tubes and boots. The Banks system uses tubes that are free of sharp bends or compressed sections. By design they feature 33 percent more internal volume over the factory setup. This streamlined delivery route translates into quicker turbo spool-up and improved airflow to the intake manifold. It also helps free up restriction that the turbocharger would have to overcome. This adds efficiency to the engine. To better understand this effect, grab a straw and try to blow through it while gently pinching it shut. You will notice that your body has to work harder to push air past the pinch point. That's exactly what your turbo has to do to overcome boost tube restrictions.
Other key factors to consider are boost tubes and boots. The Banks system uses tubes that