Ford Big Hoss Bundle 6.0L Power Stroke, '03-06

Gale Banks Engineering

F-250/350 PICKUP & EXCURSION: Banks’ Big Hoss Bundle gets your Power Stroke ready for serious action! You get it all—Banks’ exclusive Techni-Cooler charge-air cooler with the High-Ram inlet casting, which maximizes the density and flow of air into the engine; Six-Gun Diesel Tuner and Speed-Loader; stainless 4” Monster exhaust, and DynaFact gauges. The mind-blowing result? Up to +138 hp and +231 lb-ft of continuous, useable power!

Big Hoss Bundle
Includes: Techni-Cooler charge-air cooler assembly with huge 3.5” boost tubes and High-Ram intake; Six-Gun Diesel Tuner with Speed-Loader upgrade; Stainless, 4” Monster exhaust with constant-diameter turbine outlet pipe (’03 models include built-in resonator), intermediate pipe and tailpipe; Polished-stainless, 4" polished-stainless straight-through Monster muffler with exclusive expansion chamber; 5” polished-stainless double-wall tailpipe tip with rolled edge; Exclusive electronic DynaFact pyrometer and boost gauge assembly

Six-Gun Diesel Tuner
Banks’ Six-Gun Diesel Tuner provides industry’s highest proven horsepower and torque, with six levels of power easily adjustable on-the-fly. Only Banks’ Six-Gun is Stacked for Power to tune all three diesel fueling parameters—pulse width, timing and fuel pressure—all in one device. Plug-and-play Six-Gun Tuner has calibration that keeps the turbo in a safe range, and contains AutoRate, an electronic powertrain management system that automatically adjusts power output to a safe level for prevailing conditions. AutoRate includes: torque converter clutch lockup protection; intelligent fuel delivery for smooth shifting (a Banks Exclusive!); exhaust gas temperature limiting (Speed-Loader upgrade monitors EGTs and regulates fuel delivery, if required, to safeguard the engine); coolant temperature monitoring; and cold engine protection. ActiveSafety features further safeguard the engine and transmission with additional exclusive Banks features: FMEA (Failure Modes Effects Analysis), a Banks design process ensuring that Six-Gun electronics will in no way impact the durability or function of the onboard electronics); software that monitors and diagnoses itself to ensure proper function; and self-monitoring hardware that provides automatic bypass should something malfunction. By far, the most performance, value, safety and advanced engineering of any tuner, anywhere.

Speed-Loader
Banks’ Speed-Loader was made for off-road pullin’ and draggin’. This small wonder increases the output of your Six-Gun Tuner by 21 hp and 32 lb-ft with a simple inline adapter. Once you hook up Speed-Loader with its high-quality temperature probe, you’ve got Temperature Limiting Control. Speed-Loader safeguards your engine by limiting fuel delivery as exhaust gas temperature increases.

Techni-Cooler charge-air cooler
The stock system limits your power by letting the boosted air lose pressure between the turbo and the cylinder head. Banks Techni-Cooler with its huge 3.5” boost tubes and superior tube-and-fin intercooler design work together with Banks High-Ram inlet casting to remove pressure-robbing restrictions and pack more cool air into the engine. Denser and more oxygen-rich, cool air produces the greatest combustion and the most power while helping minimize exhaust gas temperature. Techni-Cooler delivers the maximum reduction in boost air temperature with a minimum loss of boost pressure. At the same time, the necessary airflow for engine cooling is not compromised. The photo above shows Banks Techni-Cooler design (front) compared to the stock intercooler.

High-Ram air-inlet casting
The Techni-Cooler creates cooler, denser air, and Banks' High-Ram intake, with its larger size and less restrictive shape, does a far better job than the puny stock intake of flowing that oxygen-rich air into the cylinders. High-Ram increases boost without raising backpressure at the turbine, resulting in instant torque, a more responsive engine and greater fuel efficiency.

Monster muffler
Replaces the factory's restrictive muffler with Banks' polished-stainless steel Monster muffler, featuring a straight-through 4"-diameter flow-path with Banks' designed expansion chamber, which dissipates the annoying mid-range exhaust drone so prominent in competitors’ straight-through mufflers. Utilizes spun ceramic, very-high-temperature packing. Delivers an authoritative—but never intrusive—exhaust sound.

Monster exhaust
Banks stainless, 4” Monster exhaust outflows stock and the competition, and preserves diesel durability by keeping the turbine outlet EGT safely at or below factory specs. The streamlined intermediate pipes and tailpipe are formed of heavy-duty, constant-diameter tubing to dramatically reduce backpressure (by 73%). The turbine outlet pipe with Banks-designed resonator eliminates screechy turbo noise (resonator for ’03 Power Stroke only). Huge 5" polished-stainless steel tailpipe tip sports a rolled edge. Double-walled design with 1/2" air gap keeps heat from tarnishing exterior mirror finish. Adjustable clamp for positioning on tailpipe.

DynaFact gauges
Banks’ exclusive DynaFact electronic gauges offer precision that can’t be matched by mechanical gauges. The pyrometer provides exhaust-gas temperature (EGT) measurements that are accurate within ±15° F at maximum operating temperatures. The pyro's spring-loaded, jeweled movement is resistant to vibration and sports a lit, easy-to-read 0-1500° F face. Banks' 0-50 psi boost gauge monitors power and turbo performance. Includes 2-gauge mounting panel. Top-mount and/or pillar-mount options available.

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