Back in the March issue's "Trailering" article ("Big Boost"), Boating World touted the benefits of improving your tow vehicle's overall performance by increasing airflow in and out of the engine through a variety of aftermarket product upgrades. Doing so results in more power, and likely improved fuel efficiency as well. On the heels of those recommendations, BW has decided to install many of those upgrades onto a project vehicle and report the real-life test results. To accomplish this task, we enlisted the aid of Gale Banks Engineering (www.bankspower.com) — a renowned specialist in manufacturing aftermarket engine power systems for pickup trucks, sport utility vehicles and motorhomes for more than 50 years.

MORE POWER, BETTER MILEAGE

The platform for this test is a 2005 Ford F-250 CrewCab pickup with a long bed and four-wheel drive, powered by a 6.0L turbodiesel engine. A Banks Power Pack system, which consists of a series of components specifically designed to improve tow vehicle performance, is installed into the truck. (A similarly designed Big Hoss Bundle is packaged for sport trucks.) To eliminate guesswork on performance gains, the truck is put on a dynamo-meter to measure true horsepower and torque both before and after the upgrades.

The dyno is set up to simulate running up a grade hauling a load with the overdrive locked out. Off the dyno, before-and-after acceleration runs and fuel tests are performed — both with and without a boat in tow — and the results are impressive.

Dyno testing reveals that the Banks Power Pack increases the Ford F-250's horsepower by 125.7 at 3400 RPM. That represents a 54.5-percent gain. In fact, a minimum 52-percent horsepower gain is recorded throughout the entire 2400- to 3400-RPM range. This much additional horsepower can be an advantage when towing. And the zippy difference felt behind the wheel is amazing, especially without a boat in tow.

Engine torque also improves dramatically as a result of the Power Pack. It's most notable at 2600 RPM, where stock torque soars from 417.9 pounds per foot to a remarkable 650.3 pounds per foot — a 232.4-pounds-per-foot (or 55.6-percent) increase. The additional pulling power offered by the Power Pack is a tow vehicle enthusiast's dream come true.

As the test data box above shows, acceleration times were up across the board in both towing and non-towing road tests. The greatest improvements came above 30 mph. For instance, 40- to 60-mph runs — which occur when passing another vehicle or merging into traffic — see the best percentage gains (39.3 percent) in towing applications where you need it most.

It should be noted, however, that the Banks Power Pack comes with six

different mode settings, which permit you to fine-tune the vehicle's performance depending on its load. If achieving faster times in lower RPM ranges (as opposed to high RPM speeds) is preferred, you merely have to change modes. You can do this on-the-fly,

with the simple push of a button on the Banks PDA. Such versatility is another great advantage of this system. In addition to achieving more power, the Banks Power Pack also increases fuel economy by nearly 10 percent when towing, and a little more than 7 percent when not towing. Any improvement in your gas mileage is welcome — especially when you consider the addition of more than 125 hp to the equation — and the Banks Power Pack gives you the best of both worlds. Once again, however, by spending time dialing into the six PDA modes, you may be able to see even better results and more fuel improvements.

HOW IT WORKS

So how does the Banks Power Pack deliver such dramatic performance gains? Basic-ally, it achieves this by replacing restrictive stock intake and exhaust components with free-flowing parts. Not unlike people, engines breathe — and the better they breathe, the better they'll perform.

The Power Pack also includes Banks' extra-thick-core Techni-Cooler intercooler system, which allows cooler, more-dense air to pass from the turbo charger to the engine. Cooler, denser air carries more oxygen, resulting in better fuel combustion and lower exhaust gas temperatures — all of which increases usable power. And unlike the stock intercooler used with Ford 6.0L Power Stroke engines — which comes with plastic end tanks held in place with weak tabs — the Banks Techni-Cooler utilizes superior welded aluminum end tanks that will not blow out under stress. It also employs high-performance 3.5-inch boost tubes for increased flow in and out of the intercooler.

The Power Pack system also replaces the small, restrictive stock intake manifold with a much larger high-ram unit that allows for greater boost with less backpressure. Another substantial upgrade is the more aerodynamic ram-air intake system, which houses a dome-shaped cotton filter in lieu of the standard air-restricting paper filter. According to Banks, it provides 37 percent better airflow. And unlike the stock filter that has to be replaced from time to time, the easy-to-access Banks

filter can be cleaned and reused.

Another Power Pack benefit is Banks' Monster Exhaust system with massive

4-inch streamlined pipes, which are manufactured from stainless, heavy-wall tubing. Coupled to this is the Monster Muffler, designed for straight-through exhaust flow. With the test vehicle, BW opts for dual exhaust tips, which are polished stainless steel. According to Banks, the entire exhaust system improves airflow by as much as 92 percent.

The control center behind the Power Pack is Banks' OttoMind 6 diesel tuner, which controls pulse width, timing and fuel pressure, and incorporates numerous powertrain and electronic safeguards.

It comes included with either a manual knob switch or a push-button PDA that permits you to change between six power levels, including a Fuel Economy mode. BW opts for the PDA, which offers all the benefits of a standard PDA (Blue-tooth wireless technology, MP3 play, audio and video file storage, etc.), but also adds an array of built-in engine and Power Pack functions.

SUMMARY

If you're an experienced mechanic, you can install the Power Pack upgrades yourself over a weekend. The instruction manual is informative and easy to follow, and technical assistance is just a phone call away. The alternative is to take it to an automotive center for installation, and the folks at Banks can suggest qualified professionals across the country.

The Banks Power Pack system does wonders for the project Ford F-250.

Not only is there a significant increase in horsepower and torque, but installing

it results in better gas mileage. Whenever you add power and save fuel, you inherently have a more efficient system. The complete system retails for around $3,000, depending on where it's purchased.