WEEKENDS SIDE JOB: banks turbo swap

[IDIoit]

hay guys, im doing another first this weekend.
I am taking off a banks set up off 1 truck, and installing it to another.
trade work for getting boat parts powder coated!

truck the banks is going on is a 91 F350 CC FB 4WD 7.3/auto

no engine work will take place, besides the turbo itself.
ive told him that my opinion is to do head gaskets and studs, but he does not want to get that deep into it.
I suspect he will try to get me to do it later.

no pics yet as the donor vehicle is not here yet.

ill try to take pics for the people that would like a step by step tutorial.

this is my first round with a banks set up, but I assume I have everything I need,
only thing I forsee needing is a valley pan grommet if they mount the same way, which I suspect isn't too much different from a ATS

 

[laserjock]

There is a write up in the tech articles with the manual I think. The manual is available from banks still as well. If you can't find it I have it downloaded I think.

 

[IDIoit]

ill dig it up if I need it.
both engines are 7.3's so seeing it installed is most likely all I need.

 

[IDIoit]

Here's both trucks. Engines hot. So it looks like it's time to change a prop shaft seal and take the kids to the beach for a couple of hours.

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[IDIoit]

awesome tech article from @FORDF250HDXLT

http://www.oilburners.net/forums/sh...urbo-sidewinder-kit-(w-instructions-amp-pics)

no reason to do a 101, but ill keep pics of the progress, and any unforeseen issues.

 

[The Warden]

Is the donor truck also a slushbox? IIRC the transmission dipstick is different and needs to be swapped...I'm not sure about the Banks setup, but I know that ATS requires it.

 

[laserjock]

That's the older Banks too so it may not be the same as the right up.

 

[IDIoit]

well the DP has 4 broken bolts, that the owner gets to deal with.
ive got just bout everything off except the adapter on the back of the pass side head.

slip fit exhaust is a biatach!

 

[gandalf]

I have the installation manual for the gen 1 Banks if you need it. It's to big to post here, so I'd need an email address.

 

[IDIoit]

It's pretty straight forward, but I appreciate the gesture!

Down pipe gaskets are gonzo.
Don't think any of the gasket material at the local auto stores will work.

Truck #1 back to N/A.
Need a CDR grommet and its done.

Took me 4 hours to pull it off.
And get her buttoned up.

Customer is getting a grommet.
And repairing the broken bolts on the hot side.

These banks kits are a PITA!!
Hope the install goes smooth.

One issue I see is the trans dipstick
May need your help with that Ken

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[Shawn MacAnanny]

Man i think any turbo exhaust work is literally the worst thing to have do haha. I'm sure you already know the weld the nut to the broken stud trick, but i actually just learned that this weekend when i was replacing the exhaust manifold on my PSD. It had been broken for a couple years before i got the truck i was going to drill it out but i couldnt get a drill in there, i looked up videos and it damn sure worked. Mine was broken almost 1/4" below the head surface and had couple years of rust and carbon build up, i still got it to back out with just a pair of channel locks


https://www.youtube.com/watch?v=3_eCEecA28k

 

[IDIoit]

yea, I know all about the successes and unsuccessful attempts of getting broken studs out of a hole.

the guy im doing this for is a fabricator by trade, and since I pretty much know the in's and out's of these trucks,
he asked me to do it.

well when I broke the first one, I told him that im not fixing these lol
he said he would do it.

when I break a stud off and threads are showing, I put a nut on it, and TIG them, it puts more heat on the stud, and it usually comes out with ease.
sometimes they break, but more than often, it works.

if the threads are below, I chuck it up in the mill.
that way I can get the exact center, then work my way up in drill sizes.

ill do the wrenching. but things like this, I dislike doing on my projects lol
plus he's got the good carbide bits.

so that's where im at.

no one had a CDR grommet.
I had to make one from a OEM turbo grommet, and a piece of hose with some RTV.
it should work fine.

truck #1 just needs some little exhaust work. which he will do.
im not getting paid enough to open my c02/AR

I think he wants to do new exhaust anyway.

the turbo is with him while he repairs the threads.

hopefully he gets it back to me tonight, along with exhaust gaskets.

I really dislike this system.
I prefer v-band clamps and such.

the banks bracket to the turbo from the pass side head is a joke.

 

[icanfixall]

Slip fit exhaust sucks the big one. For me that is the WORST part of removing my Banks sidewinder turbo. That down pipe MUST come out before you are able to reach many support bracket bolts. Sadly Banks supplies that terrible pipe clamp for the down pipe to the exhaust pipe before the muffler. And no amount of pulling.. Twisting or hoping gets it off. Its cutting torch time. But... I fixed all that when I changed me complete system from down pipe back. I had the muffler shop make my down pipe a true 3 inch opening. Then they swedged down the 4 inch to 3 inch and I supplied a clamp that fits over the 2 pipes. Its a bank clamp as seen on many better built exhaust systems like on semis and the likes. Now I loosen 2 bolts and the down pipe slides out easy peasy....

 

[IDIoit]

Slip fit exhaust sucks the big one. For me that is the WORST part of removing my Banks sidewinder turbo. That down pipe MUST come out before you are able to reach many support bracket bolts. Sadly Banks supplies that terrible pipe clamp for the down pipe to the exhaust pipe before the muffler. And no amount of pulling.. Twisting or hoping gets it off. Its cutting torch time. But... I fixed all that when I changed me complete system from down pipe back. I had the muffler shop make my down pipe a true 3 inch opening. Then they swedged down the 4 inch to 3 inch and I supplied a clamp that fits over the 2 pipes. Its a bank clamp as seen on many better built exhaust systems like on semis and the likes. Now I loosen 2 bolts and the down pipe slides out easy peasy....

I have a v-band on my exhaust housing to DP and on the DP to exhaust.
makes working on it a hell of a lot easier..

yes these slip fits suck!!!
I wasn't able to get the down pipe out before the support bracket,
so I unbolted the support bracket from the bottom with a bunch of extensions and a swivel socket. wasn't too bad.
but I got the turbo out and the DP came right out.

I sawzaw'd the DP right before the trans cross member.
luckily he is doing the exhaust.
so the major dilemma for me is 2 things.

fixing the up pipe I put a hole in with an air hammer trying to pry the 2 apart.

and the AT dipstick tube.
for this, I will cut the steel tube and reroute it, after the DP is in place.

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[Shawn MacAnanny]

I ordered this cheap seat before I removed anything because I thought I was going to have to drill it, it's pretty neat though, it has a bunch of different sized "guides" to center the drill bit, provided it's broken off below the surface and somewhat flat. Definitely worth $19, it also has some hammer in extractors but I wouldn't really trust them. I had planned on using them with left hand drill bits

http://www.ebay.com/itm/261659054019