96440 v.10.0 3
1. Disconnect the negative (ground)
cable from the battery (if there is more
than one battery, disconnect both
negative cables). Secure the cable so
it cannot accidentally come in contact
with the post.
2. Raise the vehicle and support it
securely with properly weight-rated
safety stands, ramps or a commercial
hoist. Take care to balance the vehicle
to prevent it from slipping or falling.
When using ramps, be sure the wheels
are centered squarely on the topsides.
Place the transmission in park
(automatic) or reverse (manual), set the
parking brake and securely block the
wheels that are on the ground.
CAUTION:
DO NOT WORK UNDER ANY VEHICLE
SUPPORTED ONLY BY A JACK. SEVERE
INJURY MAY RESULT.
WARNING! The following step
may require the use of a torch and/
or saw. Proper safety equipment
should be used. Failure to use proper
safety equipment may result in
severe injury.
3. From under the vehicle, remove the
factory exhaust system from the catalytic
converter back. Starting at the rear of
the vehicle, remove each component
by either cutting through the pipe near
the clamps or by removing the clamps
and heating the joints with an oxy-
acetylene torch to allow crimped pipes
to separate. DO NOT CUT OR DAMAGE
CATALYTIC CONVERTER TUBING
DURING THE REMOVAL PROCESS. To
assist in removal, the T.O.P. should be
cut before the transmission if it is
going to be replaced. Remove the
hanger pins from the rubber hangers
with a pry bar. (Spray lubricant will ease
hanger removal.)
4. Remove the two (2) nuts attaching
the turbine outlet pipe (T.O.P.) to the
catalytic converter inlet. Loosen and
remove the band clamp that attaches
the rear intermediate pipe to the
catalytic converter outlet. Remove
the catalytic converter assembly from
the vehicle. Remove the band-clamp
that attaches the T.O.P. to the
turbocharger and remove the factory
T.O.P. from the vehicle. Retain V-band
clamp for re-assembly.
Note: To assist in T.O.P. removal,
remove the rear engine hoist hook by
removing the two (2) Hex screws and
remove the valve cover heatshield.
The dipstick tube may also be
removed or slightly bent to allow for
T.O.P. removal/installation. Retain all
hardware and parts for reassembly.
For Manual Transmissions only:
the
transmission will need to be lowered
to allow for removal and installation of
the T.O.P. Using a Transmission Jack,
support the rear of the transmission to
allow working room for the T.O.P. and
remove the rear transmission mount
and crossmember. Remove the Front
drive shaft support bracket from the
cab. Lower the transmission 4-6" and
remove the factory T.O.P.
The transmission may need to be
raised before the Banks T.O.P. is
installed. Install the Banks T.O.P. Raise
the transmission and reinstall drive
shaft bracket, transmission
crossmember and rear transmission
mount. Refer to vehicles owners manual
for factory Torque Specifications.
5. Loosely place the factory V-band
clamp on the Banks T.O.P. Install the
Banks T.O.P. to the turbine housing.
Loosely snug the V-band clamp
assuring
the T.O.P. is aligned properly.
Note: Reinstall the engine hoist hook
and valve cover heat shield if
previously removed.
6. The catalytic converter inlet will
need to be trimmed to accommodate
Monster Exhaust System Installation
