banks stinger plus for early 91

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Just bought a banks stinger plus kit for my moms truck. I plan on installing it this weekend and adjusting the valves while I've got it half apart. Kind of wondering how well the auto trans will hold up against 600 foot pounds of torque.

 

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Well it took about 14 hours including breakfast,dinner,laker game, and valve adjustment. Weird thing is the radiator started leaking at the lower hose bib where it is soldered to the radiator. I'm guessing that the vibration from the hole saw must have caused it. It's a small constant drip from the bottom of the bib and close to the center. Looks like a small fleck of paint is missing at that exact point. Hopefully some alumaseal will do the trick.

 

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I wouldn't trust the alumaseal to fix the radiator. I suggest you take it out and have a radiator shop solder it up. Might as well have the thing cleaned at the same time. And since the hoses are off, may as well replace them if they are old.

How does the truck run with the new "stuff" installed? Did you have a noticable improvement? Were the valves off very much?

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Stan
93 2WD extended cab, Banks Power Pack, K&N Air Filter, Auto w/4. 10 rear with gear locker, US Gear Exhaust Brake, 3. 5" Exhaust, 5K air bags, Boost/Pyro/Tach Gauges, Green/Silver, 137K

 

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OO
How difficult was the intercooler to install? Did you have to move the A/C? What type of hole saw did you use for the hole?
Matt

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90 W250, 5-speed, 3. 54 gears, 16 cm2 housing, tach, pyro, and boost gauges.

 

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The radiator is probably due to be rodded out by now anyway so I'll pull it next time I drop by. I also noticed while doing the exhaust that the output seal on the transfer case is spewing oil so I'll have to replace that too. The valves were very close. A couple tight ones and number 6 was loose on both exhaust and intake but not by much. The intecooler itself is not that hard to install. The only thing that has to be moved is the coolant recovery bottle but it goes back in the same spot with spacers. I used a regular ace bimetal 3" hole saw. It just vibrates real bad as it punches through the other side. Not enough time for a serious test drive but it spools up and accelerates faster. Banks says it adds 50hp and 100ft . lbs. I'll post a mileage report in a couple of weeks.

 

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OO, I noticed in you last post that your transfer case is leaking. My 92 had a leak around the rear output shaft. I just finished repairing it-cost me $13 in parts (seal washer, oil seal and gasket behing the seal retainer). Very simple job. If the yoke does not slide off by hand I would use a gear puller to remove it rather than trying to pry it off.

 

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Your Mom's truck have air? If so, how'd you make room for the intercooler. My AC hoses look like they'll have to be replaced on my 89 in order to install the intercooler. .

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http://coffeewithJesus. homestead.com/web1.html 89 1-ton, K&N, cleaned up exhaust, Dynomax straight-thru, rebuilt pump, intercooler, louvered fenders, 93 aftermarket smoothe grille; 78 35'Avion. Jesus saves!

 

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It does have air. The intercooler is wider than the radiator and the inlet and outlet come out on either side close to the bottom of the radiator. I did have to bend the sheetmetal rib that the hoses were clipped to just a little to clear the intercooler pipes. On the early 91 the grill has to be trimmed a little to clear. On the 89-90 the grill has to be replaced. Banks includes the new grill with those kits.

 

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Did the Banks intercooler mount between the radiator and the AC condensor, or in front of the condensor?

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http://coffeewithJesus. homestead.com/web1.html 89 1-ton, K&N, cleaned up exhaust, Dynomax straight-thru, rebuilt pump, intercooler, louvered fenders, 93 aftermarket smoothe grille; 78 35'Avion. Jesus saves!

 

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It sits in front of the condenser. I had to make some slight adjustments before tightening down all the bolts to make sure it didn't touch anywhere. I ended up with about a 1/8" clearance on one side and a 1/4" on the other. Befor I bought the system I downloaded the instalation instructions from www.dieselpage.com to see what I was getting into. That helped a lot in making the decision to buy it.

One place to disregard the instructions is the exhaust removal. Do not try to pull it apart. That is a complete waste of time on something you will be throwing in the trash. Just cut the tailpipe off at the muffler and then make a cut lengthwise at the downpipe connection making sure not to gouge the downpipe. I layed under the truck facing the front and where I could get a good foothold on the muffler. Then I just pushed up and back till it hit the frame and then let it drop all the way down repeating this until it fell of.

One of the reasons for installing the system was because mileage had dropped from 20 to 16. It's up to 19 now with the install but the truck still has a rough idle and should be getting 20 to 22 easy. The truck has under 200,000 miles and it sounds like there's a bad injector or pump already. I would expect more from cummins but maybe they subed the fuel system out to international that year.

 

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I had fewer miles than that when I had to rebuild my pump. Bigger injectors should add to pump life! I'm concerned about mounting the intercooler in front of the AC condensor. How did it affect your AC performance?

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http://coffeewithJesus. homestead.com/web1.html 89 1-ton, K&N, cleaned up exhaust, Dynomax straight-thru, rebuilt pump, intercooler, louvered fenders, 93 aftermarket smoothe grille; 78 35'Avion. Jesus saves!