Ford's 6.8L gasoline-fueled V-10 Triton is a torquey over-square engine that comes in most F-250 Super Duty pickups as well as several popular motorhome chassis. It's a tough 415ci engine that, in stock trim, puts 310 hp and 425 lb-ft to the flywheel, and it loves to tow heavy-duty loads. It's reliable and pretty thrifty on fuel, at least as far as a 415-inch engine can be thrifty. In short, Ford's V-10 is well-engineered, so when you make changes, they better be good ones.
Gale Banks Engineering (GBE) is known for making good changes to engines. The company's been at this a long time and has a solid track record -- literally. GBE has helped set and break a ton of racing records in just about every venue. So when offered a chance to review and test the company's PowerPack system for '99-'04 gasoline-fueled 6.8L V-10 Triton-equipped Super Duty pickups, we didn't hesitate.
Our test mule, a brand-new '04 Ford F-250, was strapped on to GBE's Mustang dyno for a baseline test the day before the installation of the PowerPack. The stock truck produced 200 hp at 4,300 rpm and 268 lb-ft of torque at 3,700 rpm at the rear wheels on GBE's Mustang chassis dyno. As you can see from the dyno charts, it made substantially more after GBE installed the PowerPack system.
01. The PowerPack system includes a Banks Ram-Air intake; Electronic OttoMind engine-calib
As good as the dyno figures are for this system, the ultimate test is driving it on the road. Fortunately for us, the owner of this truck was taking it on the road for a month, hauling a 10,500-pound fifth-wheel trailer, so we were able to get a lot of good information on driveability, reliability, and fuel efficiency. After living with the system for 7,500 miles, the overall impression of the Banks system is completely positive.
Especially regarding fuel efficiency. The owner reports he got between 8-1/2 to 9-1/2 mpg while towing, depending on the grade of the road he traveled. And on empty, he got as good 14-1/2 mpg. Driveability and throttle response were much better, and it pulled hard when he needed it. The truck was noticeably quicker to accelerate and more responsive to throttle input, making it a lot more fun to drive. When he needed the torque, he'd gear down and put it at the torque peak, and the V-10 proved to be as tough as the toughest grade he needed to climb.
Hey, what more can you ask of a product? More power, better mileage. It's sounds like a good combination to us.
02. Banks' Ram-Air intake includes a molded Ballistic filter housing and a lifetime high-f
03. Banks' optional OttoMind engine-calibration module matches the fuel curve to airflow i
04. A side-by-side comparison of the stock exhaust system shows both the increase in tubin
05. GBE stainless TorqueTubes are tuned-length parallel five-tube exhaust manifolds. Banks
06. The streamlined exhaust pipe and 3-1/2-inch tailpipe are formed of stainless heavy-wal
07. In addition to the smooth bends of the 4-inch exhaust outlet, the GBE system replaces
6.8L Triton V-10 iron-block, aluminum heads
•Bore/Stroke: 3.55 x 4.16 in
•Displacement: 415 ci, 6,802 cc
•Compression ratio: 9.0:1
•Fuel injection: Sequential multiport electronic
•Valvetrain: SOHC, 2 valves per cylinder
•Horsepower: 310 hp @ 4,250 rpm
•Torque: 425 lb-ft @ 3,250 rpm
Quick Dyno Spec Check
Horsepower, Best Gain
•Stock: 168 hp @ 5,000 rpm
Banks: 220 hp @ 5,000 rpm
Gain: +52 hp (31%)
Horsepower, Peak to Peak
•Stock: 200 hp @ 4,300 rpm
Banks: 227 hp @ 4,600 rpm
Gain: +27 hp (14%)
Torque, Best Gain
•Stock: 230 lb-ft @ 2,800 rpm
•Banks: 291 lb-ft @ 2,800 rpm
•Gain: +61 lb-ft (27%)
Torque, Peak to Peak
•Stock: 268 lb-ft @ 3,700 rpm
•Banks: 305 lb-ft @ 3,700 rpm
•Gain: +37 lb-ft (14%)
0-60 mph, Loaded
•Stock: 28.10 sec
•Banks: 25.50 sec
•Gain: -2.6 sec (9%)
08. This shot of the tech fastening a header bolt shows that for do it yourselfers, there'
09. Banks' headers have what the company calls the "PowerPickle" high-velocity pulse conve
10. All the fabrication of the exhaust system is OE-quality. Check out how well the header
11. The Y-pipe merge area also shows the high quality of the bends and welding. In our opi
12. Installing the polished-stainless 4-inch tailpipe tip is the finishing touch on the ex
13. Installing the Ram-Air intake and molded Ballistic filter housing is a basic remove-an
14. The Ford's engine management computer is under the dash on the driver side. Plugging t
15. The author and Gale Banks Engineering's performance engineer are suitably impressed wi
16. The GBE PowerPack system is 50-state emissions-legal. The sticker needs to be updated