The real limit on a Ford 6.0L is not just fuel delivery. If you add fuel without improving the rest of the system, you build heat, stress the transmission, and leave airflow bottlenecks in place. That is why the Big Hoss Bundle attacks the whole package. The Six-Gun tuner changes injector pulse width, fuel pressure, and timing, then ties that added power to transmission line pressure with built-in TransCommand. On the air side, the larger intercooler, larger boost tubes, and larger intake manifold move more cooled, denser air through the engine. On the exhaust side, the Banks Monster Exhaust System reduces restriction so the engine can push spent gases out easier. Just as important, the gauge package keeps an eye on exhaust temperature, boost, and transmission temperature so you can use the power without flying blind. Put together, the system is about making bigger 6.0L power in a way that supports reliability instead of working against it.
The project centers on a new Ford F-250 Super Duty with the Power Stroke diesel, with the goal of extracting substantially more power and torque without damaging an expensive truck in the process. In the diesel world, performance gains are especially attractive because power and torque are central to how these trucks tow, haul, and accelerate. The challenge is not simply making more power, but doing it in a way that remains reliable and does not create transmission slip, excessive exhaust heat, or other failures.
To accomplish that, the build uses Gale Banks Engineering's Six-Gun Bundle. The package is presented as a complete diesel power system rather than a single add-on, addressing fuel delivery, air intake, charge-air cooling, and exhaust flow together. The sequence of the installation follows that engineering logic: first the electronic tuning and monitoring, then the intercooler and intake-side hardware, and finally the exhaust system.
The first major component is the Banks Six-Gun electronic diesel tuner. Its purpose is to alter the fuel system in three specific ways: injector pulse width, fuel pressure, and fuel timing. Injector pulse width determines how long the injector remains open. Fuel pressure affects how much fuel enters while the injector is open. Fuel timing controls when the injector opens and closes. The claim made for the system is that it adjusts all three of these parameters, rather than changing only one or two.
The tuner offers six selectable power levels. By changing settings, the driver can choose how aggressively the truck is calibrated. In this application, the Six-Gun is said to provide gains of up to 120 horsepower and 220 lb-ft of torque on its own. An important part of the package is the built-in TransCommand function, which calibrates fueling to transmission line pressure. The stated purpose is to prevent slippage and transmission damage when torque rises, making the added power more usable and less likely to harm the drivetrain.
Installation begins under the hood on the driver's side by removing the battery cover to access the truck's computer area. The Six-Gun module is mounted behind the power steering reservoir, which is identified as a suitable location on the Ford Power Stroke. The supplied harnesses are designed with different connector ends so they only fit their intended sockets, reducing the chance of incorrect installation. One additional harness is routed to the passenger side and connected to the MAP sensor, completing the underhood electrical connections.
Inside the cab, the selector switch must be mounted where the driver can easily reach it without cluttering the interior. Banks recommends placing it in the upper dash area. A paper template is included to mark the drilling points, but the dash cover must first be removed. The factory Ford radio removal tools included in the kit are used to pull the radio and release the dash trim. Once the panel is off, the holes can be drilled and the selector switch mounted cleanly in place.
An optional companion piece called the Banks Speed-Loader plugs into the wiring harness from the selector switch. Used with the Six-Gun system, it is said to add another 30 horsepower. That raises the combined increase from the tuning package to roughly 150 horsepower and 260 lb-ft of torque before any intake or exhaust hardware is changed.
Because diesel performance modifications can quickly raise boost, exhaust heat, and transmission load, the build includes a set of monitoring gauges mounted on the A-pillar. The three parameters chosen are exhaust gas temperature, turbo boost, and transmission temperature. The pillar pod itself installs with plastic rivets, after which the wiring and sensor connections are routed into place.
The transmission temperature and boost gauge hookups are relatively straightforward, but the exhaust temperature probe requires more work. To install the pyrometer probe correctly, the driver-side front tire is removed and the inner fender is taken out for access. The driver-side exhaust manifold is then unbolted and removed. A hole is drilled and tapped in the manifold, and the pyrometer probe is installed there.
The probe location is important because it measures exhaust gas temperature before the turbocharger, which provides a more accurate reading than a post-turbo location. Removing the manifold before drilling is also critical. If the manifold were drilled in place, metal shavings could remain inside, pass through the turbo, and destroy it. For that reason, the manifold must not only come off, but must also be cleaned thoroughly before reinstallation. Once the manifold is back on and the wiring is connected, the truck has the instrumentation needed to safely monitor the added power.
After the tuner and gauges are installed, attention shifts to the intake side. The stock Power Stroke already uses an intercooler, which resembles a radiator but carries no liquid. Instead, hot compressed air from the turbocharger passes through it, is cooled, and then flows into the intake manifold. Because cooler air is denser, reducing charge-air temperature improves the engine's ability to make power.
The Banks replacement intercooler is larger than stock, with a thicker core, redesigned end tanks, and larger outlets. The stated goal is improved cooling efficiency and better airflow. To complement the larger intercooler, the kit also includes larger inlet and outlet tubes and a larger intake manifold. Together, those parts are intended to increase both airflow and charge-air volume, supporting the higher fueling levels introduced by the Six-Gun tuner.
Although the factory intercooler appears buried behind the front structure, radiator, condenser, and other components, it can be removed through the top without dismantling the entire front of the truck. The process starts by removing the rubber shroud to expose the intercooler area. Reference marks are made around the hood latch before it is removed so alignment can be restored during reassembly.
Next, the air-conditioning condenser is unbolted, followed by the two radiator support brackets and the radiator support crossmember. With those pieces out of the way and the intercooler disconnected, the original unit can be lifted out from above. The new Banks intercooler is then lowered into position and the surrounding hardware is bolted back together.
With the cooler installed, the stock boost tubes and intake manifold are removed. The new Banks intake manifold slides onto the supplied studs and bolts into place. The new inlet tube is connected between the intercooler and the manifold using Banks connectors. The other boost tube also installs directly, although some trimming is required at the corner of the fan shroud and the battery box to create clearance for the larger tube. At that point, the intake and charge-air side of the system is complete.
The final hardware change is the Banks 4-inch Monster Exhaust system. The system uses large-diameter stainless steel tubing and is described as more than just oversized pipe; it is presented as a complete exhaust layout engineered for flow and fit. At the front is a new turbine outlet pipe with a resonator, positioned ahead of the catalytic converter.
The stock catalytic converter remains in place for legal compliance. Behind it, the system continues as a cat-back exhaust. The mounting hangers are welded directly to the pipe, and the system includes a large stainless steel muffler intended to provide both the desired flow and exhaust note. The 4-inch tubing continues all the way to the rear, ending in a large polished tip.
Installation is described as straightforward because the exhaust sections slide into place under the truck. Once fitted and secured, the truck has the full Six-Gun Bundle installed: tuner, gauges, intercooler, boost tubes, intake manifold, and 4-inch exhaust.
The driving evaluation focuses on how the truck behaves through the Six-Gun's six power levels. Level one is effectively stock, so it serves as the baseline. Levels two and three noticeably wake the truck up, with power increasing step by step. At those settings, the truck becomes more entertaining to drive while still remaining practical for normal use and towing.
Level four is characterized as a balanced calibration, offering strong towing and hauling performance without becoming so aggressive that traction immediately disappears. Level five pushes the truck into hot-rod territory. Once the turbocharger spools, the truck accelerates hard enough to pin the driver in the seat, and tire wear starts to become a real concern.
Level six is the most aggressive setting. At that point, there is no ambiguity that the diesel truck has become a serious performance vehicle. When the turbo comes up and the engine enters the power band, the torque surge is strong enough to force the driver back in the seat, and the rear tires can easily turn into smoke. The overall conclusion is that the Banks package transforms the Power Stroke into a much more powerful truck while preserving the supporting systems needed to manage that power.