Technical > Installation Guide
Banks’ Big Hoss Installation, Part 1: Intercooler And Intake Install
Goading More Horses From a Ford F-250
story and photos by Steve Temple
The Banks Big Hoss Bundle combines all of the company’s diesel performance upgrades into one package.
Regular readers of Off-Road Adventures who are looking for performance gains on their diesel-powered trucks may recall our recent tech feature on the Banks Six-Gun system. Combined with some additional performance options to create the Banks Big Hoss Bundle, this upgrade can markedly raise the power output on all three major U.S.-brands of later-model diesel engines (GM, Dodge and Ford). On the Ford specifically, it pumps up output on the 6.0-liter by as much as 138hp and 231 lb./ft. of torque, all with the simple twist of a dial on the dash. This knob manipulates three basic engine parameters: fuel pressure, timing and injector pulse width.
Buy The Banks Big Hoss Bundle from www.4wheelparts.com.
 1. Remove stock tube from the hot side of factory intercooler. |
2. Use two pry bars to lift out core support. |
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3. Remove stock intercooler (the Banks intercooler fits in factory location for intercooler). |
4. Several other factory parts that have to be removed as well: dual batteries, hold-downs for radiator and condenser, and airbox. |
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5. Ford factory vs. Banks intercooler: note the larger diameter of the intercooler tubing (2 1/8 vs. 3 inches) for increased air flow and heat transfer. The Banks intercooler is also more than an inch thicker (2 7/8 vs. 1 3/4 inches thick) for more surface area. |
6. Intercooler tubes, factory vs. Banks. The cool side is shown on the left (driver’s side) and hot side on right (passenger side). Note the crimping of the stock component to fit around alternator. It’s quick to fit it, but it restricts airflow and impairs cooling. |
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7. Trim the battery tray for clearance on tube on passenger side. |
8. Mini “lift block” for the driver’s side tray needs to be installed as well. |
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9. High Ram intake features an enlarged plenum and larger diameter opening to fit the larger intercooler tube. |
10. Note that the fan shroud has to be trimmed to make room for it. |
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11. Slide in Banks intercooler with factory mounting pads and hold-downs. |
12. Use a bit of silicone spray to lubricate the rubber hose connectors before sliding them on. IMPORTANT: Make sure the bolt on the clamp is positioned away from the underside of the hood, or the torquing of the engine may poke a hole in the hood. |
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13. Install passenger-side intercooler tubes. |
14. Here’s the completed install of the Banks intercooler and its tubing; stock components (fan shroud, batteries, airbox, etc.) still need to be |