03/07/06 PN 96482 v.2.0

Banks Split DualMonster® ExhaustSystem2003-2004 Dodge 5.9L Cummins ISB Pickup Trucks

THIS MANUAL IS FOR USE WITH MONSTER EXHAUST,

SYSTEMS 48702-48705

Gale Banks Engineering 546 Duggan Avenue • Azusa, CA 91702 (626) 969-9600 • Fax (626) 334-1743

Product Information & Sales: (800) 438-7693Customer Support: (888) 839-5600 Installation Support: (888) 839-2700

bankspower.com

©2006 Gale Banks Engineering

Owner’sManualwith Installation Instructions

2 96482 v.2.0

Dear Customer,

If you have any questionsconcerning the installation ofyour Banks Power System, pleasecall our Technical Service Hotlineat (888) 839-2700 between 7:00am and 5:00 pm (PT). If you haveany questions relating to shippingor billing, please contact ourCustomer Service Department at (888) 839-5600.

Thank you.

1. For ease of installation of yourBanks system, familiarize yourself withthe procedure by reading the entiremanual before starting work.

2. The exploded view (Figure 1)provides only general guidance. Referto each step and section diagram inthis manual for proper instruction.

3. Throughout this manual, the leftside of the vehicle refers to thedriver’s side, and the right side to thepassenger’s side.

4. Disconnect the ground cable fromthe battery (or batteries, if there aretwo) before beginning work.

5. Route and tie wires and hoses aminimum of 6" away from exhaustheat, moving parts and sharp edges.Clearance of 8" or more isrecommended where possible.

6. When raising the vehicle, support iton properly weight-rated safetystands, ramps or a commercial hoist.Follow the manufacturer’s safetyprecautions. Take care to balance thevehicle to prevent it from slipping orfalling. When using ramps, be sure thefront wheels are centered squarely onthe topsides; put the transmission in

park; set the hand brake; and placeblocks behind the rear wheels.Caution! Do not use floor jacks tosupport the vehicle while workingunder it. Do not raise the vehicleonto concrete blocks, masonry orany other item not intendedspecifically for this use.

7. During installation, keep the workarea clean. Do not allow anything tobe dropped into intake, exhaust, orlubrication system components whileperforming the installation, as foreignobjects will cause immediate enginedamage upon start-up.

8. The Dual Exhaust System isdesigned to accommodate the factory-sized spare tire. If the spare tire isoversized, it may need to be removed.

9. The tip is located for single rear-wheel applications. Installation ondually systems is not recommended.

Tools Required:

• 1⁄2" and 3⁄8" drive ratchets with inchand metric sockets and 1⁄2" and 3⁄8"drive extension

• Inch and metric combination oropen-end wrenches

• Standard screwdriver

• Clean shop towels or rags

• Pry-bar

• Reciprocating saw

Highly recommended tools andsupplies:

• Inch-pound and foot-pound torquewrenches

• Compressed air source and hose

• Air pressure regulator

• Penetrating oil or light lubricantspray

General Installation Practices

96482 v.2.0 3

1. As a precaution, disconnect theground of the battery (if there is morethan one battery, disconnect both).

2. Raise the vehicle and support it withproperly weight rated safety stands,ramps or a commercial hoist. Followthe manufacturer’s safety precautions.Take care to balance the vehicle toprevent it from slipping or falling. Whenusing ramps, be sure the front wheelsare centered squarely on the topsides;place the transmission in park; set theparking brake and place blocks behindthe rear wheels. CAUTION: DO NOTWORK UNDER ANY VEHICLESUPPORTED ONLY BY A JACK.SEVERE INJURY MAY RESULT.

WARNING! The following steprequires the use of a torch and/orsaw. Proper safety equipmentshould be used. Failure to useproper safety equipment mayresult in severe injury.

3. From under the vehicle, remove theentire factory exhaust system. Startingat the rear of the vehicle, remove eachcomponent by either cutting throughthe pipe near the clamps or byremoving the clamps and heating thejoints with an oxy-acetylene torch toallow crimped pipes to separate. DONOT CUT OR DAMAGE CATALYTICCONVERTER TUBING DURING THEREMOVAL PROCESS. Remove thehanger pins from the rubber hangerswith a pry bar. (Spray lubricant willease hanger removal.)

4. Remove the clamp attaching theturbine outlet pipe (T.O.P) to thecatalytic converter headpipe (orintermediate pipe if applicable) andremove the catalytic converterassembly or intermediate pipe.Remove the band-clamp that attachesthe T.O.P. to the turbine outlet elbowand remove the factory T.O.P from thevehicle.

5. Remove the V-band clamp thatattaches the turbine outlet elbow tothe turbine housing and remove theturbine outlet elbow from the vehicle.

6. Attach the supplied T.O.P. gasket tothe Banks T.O.P. Loosely place thesupplied V-band clamp on the BanksT.O.P. Install the Banks T.O.P. to theturbine housing (note: the factoryturbine outlet elbow will not be used).Loosely snug the V-band clampassuring gasket and T.O.P are alignedproperly.

7. For vehicles that are NOT equippedwith a catalytic converter, install thesupplied Banks front intermediate pipeand supplied gasket onto thepreviously installed Banks T.O.P. Placea small amount of anti-seize onto thefour (4) 7⁄16" bolts. Loosely install thesupplied 7⁄16" hardware onto the T.O.P.and intermediate pipe flange (seeFigure 1). Proceed to Step 9.

8. For vehicles equipped with catalyticconverters:

IMPORTANT: If the vehicle isequipped with a catalyticconverter, it should be inspected.Diesel catalysts may becomeplugged with soot and can cause arestriction to exhaust flow,impeding performance. Shine apowerful flashlight into the inletend of the converter. Observe thelight through the other end of theconverter. The full circle of theflashlight should be visible withoutany blockage in the gridwork of thecatalyst. If excessive soot isobserved, the catalyst may need tobe cleaned. TAKE PRECAUTIONS toavoid blowing soot toward thework area or where it could beinhaled. ALWAYS use breathingprotection. Also inspect thecatalyst for damage (i.e. chips, bentcorners, etc.) to the gridwork. If

Monster Exhaust System Installation

4 96482 v.2.0

General Assembly Diagram

Figure 1 03-04 Dodge Split Dual Monster Exhaust Parts List

1 23

2028

18 19

18 19

5

22

22

7

89

10 11

13

421

21

21

6

1415

1817

19

16

12

2423

Item Description Qty P/N

1 V-Band Clamp (1) 92887

2 Turbine Outlet Gasket (1) 93005

3 Monster Turbine Outlet Pipe (T.O.P.) (1) 53270

4 T.O.P Gasket (4-bolt) (1) 93210

5 Front Intermediate Pipe (1) 53272(Non-Cat. Conv. Systems Only)

6 Headpipe (Cat. Conv. Systems Only) (1) 53271

7a Intermediate Pipe SCLB / CCSB (1) 53292

7b Intermediate Pipe CCLB (1) 53293

8 Front Hanger Clamp (1) 53284

9 Monster Muffler (1) 53285

10 Rear Hanger Clamp (1) 53286

11 Y-Pipe (1) 53287

12 Left Tailpipe (D/S) (1) 53288

13 Right Tailpipe (P/S) (1) 53289

14 Frame Hanger Bracket (1) 53290

15 2"x2" Hanger Plate (1) 53291

16 Rubber Hanger (1) 53732

17 7⁄16-20 x 4" Hex Bolt (1) 91635

18 7⁄16" SAE Washers (10) 91601

19 Nut, Crimplock, 7⁄16-20" (5) 91619

20 Hex Bolt, 7⁄16-20x1.25" (4) 91629

96482 v.2.0 5

1 23

2028

18 19

18 19

5

22

22

7

89

10 11

13

421

21

21

6

1415

1817

19

16

12

2423

Item Description Qty P/N

21 3-1⁄2" Exhaust Clamp* (2)* 52468

22 4" Exhaust Clamp (2) 52470

23 Black 5" Cable Ties (3) 62001

24 Banks Power Decals (2) 96009

* Catalytic converter sytems receive three (3) 31⁄2” clamps.

6 96482 v.2.0

your catalytic converter isdamaged, it may be covered underyour vehicle’s emissions warranty.

A) With the catalytic converterremoved from the vehicle and theheadpipe removed from the converter,measure 13" inward from the outlettubing rim (3-1⁄2" of tubing from theoutlet weld should remain). Using areciprocating saw or equivalent,vertically cut and remove 13" from theconverter outlet tubing (see Figure 2).

B) Install the supplied Banks frontintermediate pipe and supplied gasketonto the previously installed BanksT.O.P. Place a small amount of anti-seize onto the four (4) 7⁄16" bolts.Loosely install the supplied 7⁄16"hardware onto the T.O.P. andintermediate pipe flange.

C) Install the supplied 3-1⁄2" clamponto the catalytic converter inlet.Place the catalytic converter onto thepreviously installed intermediate pipe.Loosely snug the clamp on thecatalytic converter inlet.

9. Place a supplied 4" clamp onto thefront of the supplied intermediatepipe. Install the intermediate pipe ontothe catalytic converter outlet or thefront intermediate pipe. Lightly snugthe exhaust clamp near the rim of theintermediate pipe.

10. Install the front hanger clamponto the Monster Muffler inlet. Install a4” clamp onto the muffler inlet. Installthe muffler inlet onto the intermediatepipe. Insert the front hanger into thevehicle's rubber grommet.

11. Install the rear hanger clamp ontothe Monster Muffler outlet with thehanger pins facing forward. Install thetwo (2) rear hanger pins into thevehicle's rubber grommets. Orient theBanks Monster logo to be level withthe frame rail.

12. Install the Banks Y-pipe into themuffler outlet such that the outlets arepointing up. Install a 3-1⁄2” saddleclamps onto each y-pipe outlet (seeFigure 3).

13. Install the Banks hanger bracketonto the rear of the driver-side framerail. Behind the rear shock crossmember, place the hanger bracketover the frame rail on the inside. Alignthe 1⁄2” hole in the center of the framewith the hanger bracket. Install the7⁄16”x 4” bolt & washer through thebracket and frame rail. Secure the bolton the outside frame rail using the2”x2” plate, washer and 7⁄16” nut. Besure the hanger pin is parallel with theframe rail and torque 7⁄16” hardwareto 48 ft-lb (see Figure 4).

Figure 2

DRIVER SIDETAILPIPE

PASSENGERSIDE

TAILPIPE

3.5”CLAMP

REAR HANGER CLAMP

ORIENTATION OFMONSTER MUFFLER

FRONTHANGERCLAMP

FORWARD

4“CLAMP

INTERM PIPE

Y-PIPEFigure 3

DRIVER SIDETAILPIPE

DRIVER SIDEFRAME

HANGERBRACKET

7/16” BOLT& WASHER

SPARETIRE

7/16”NUT &

WASHER 2“ X 2”PLATE

Figure 4

96482 v.2.0 7

14. Install the supplied rubber hangeronto the Banks hanger bracket.

15. Install the driver-side tailpipe intothe top Y-pipe outlet. Install thedriver-side tailpipe hanger into thevehicle rubber hanger.

16. Install the passenger-side tailpipeinto the lower Y-pipe outlet. Install thepassenger-side tailpipe hanger into thevehicle rubber hanger.

17. Move the spare-tire to the rear ofthe vehicle and center between the

dual tailpipes. Tighten the spare tirewith the manufacture tire tool so thatit is retained into place (See Figure 5).

18. Un-clip the axle vent hose outletattached to the bed near the sparetire. Re-route the vent hose on top ofthe fuel tank and attach to the bedaway from the driverside tailpipe. Ziptie the vent hose and brake line to theemergency brake cable, away from thetailpipe.

19. Adjust each of the pipes toensure that all of the hanger pins are

BANKSDRIVER SIDE

TAILPIPE

ZIP TIE ONVENT HOSE

& BRAKE LINE BANKSPASSENGER SIDE

TAILPIPE

ADJUST SO THATSPARE TIRE TO

TAILPIPE CLEARANCEIS THE SAME MOVE SPARE

TIRE TOWARDSREAR OF VEHICLE

Figure 5

8 96482 v.2.0

96482 v.2.0 9

parallel with the frame-mounted pinsand fully inserted in the vehicle’srubber grommets.

20. Be sure that the two (2) tailpipesare completely engaged into the Y-pipe. Rotate the tailpipe until thehanger pins are parallel with theframe-mounted pin. NOTE:Recommended distance betweenexhaust tip and body is a half (1⁄2”)inch.

21. Beginning with clamps closest tothe catalytic converter, and workingyour way back. Align the saddleclamps at the beginning of the slots(on the 1⁄2” circle punch) and evenlytorque the 2-studs on the clamp.Figure 3 illustrates the proper locationof an exhaust clamp on a tubing joint.Torque the nuts on each of theexhaust clamps to 35 ft-lb.

22. Remove the protective coveringfrom the tailpipe tip. Caution: theprotective covering may ignite andburn if not removed prior torunning the engine.

23. Your system includes two (2)Banks power logos. The logos can bemounted 1⁄2" to 1" above the“Cummins Turbo Diesel” emblem onthe driver-side and passenger-sidefront fenders.

24. Re-connect battery terminals ifpreviously removed. Start the engineand listen for exhaust leaks. Tightenthe exhaust clamps as necessary.Whenever possible, tack weld slipconnections to prevent disengagementis recommended.

25. The Banks Monster Exhaustinstallation is now complete.

10 96482 v.2.0

Notes

96482 v.2.0 11

Notes

Gale Banks Engineering 546 Duggan Avenue • Azusa, CA 91702 (626) 969-9600 • Fax (626) 334-1743

Product Information & Sales: (800) 438-7693Customer Support: (888) 839-5600 Installation Support: (888) 839-2700

bankspower.com