The real gain here came from treating the 5.9L Cummins like an air pump. The stock truck had respectable output, but the inlet, turbine housing, exhaust, and fuel control were all limiting how much air the engine could move. The Banks PowerPack opened up the system end to end: a larger, lower-backpressure turbine housing with a better-matched actuator to bring boost on quicker and hold it longer, a freer-flowing intake path, a 4-inch stainless exhaust, and AutoMind fuel control to match fuel delivery to the added airflow. Add in boost and exhaust temperature monitoring, and you have a complete package instead of a pile of parts. On the dyno, that combination delivered about 108 more horsepower and almost 240 lb-ft of torque, with a claimed 7% fuel economy improvement.
The episode shifts from gasoline performance upgrades to diesel trucks, using a new Dodge Ram with the 24-valve Cummins as the test vehicle. The premise is that diesel engines can often gain substantial horsepower and torque without hurting fuel economy, and in this case the claim is that every modification being installed should improve both power and mileage.
The truck starts with stock output of about 180 horsepower and 410 foot-pounds of torque, which is already strong for a factory pickup. Even so, the goal is to add significantly more pulling power. To do that, the build uses a Gale Banks Engineering Power Pack kit designed to improve the engine's breathing on both the intake and exhaust sides while also recalibrating fuel delivery to match the added airflow.
The installation begins by clearing access to the turbocharger. The air inlet tube and air filter box are removed first, followed by the exhaust system. The oil drain and oil supply lines are disconnected from the turbo, and then the turbocharger itself is unbolted from the manifold and outlet tube. A rag is placed over the outlet tube opening to keep debris from falling inside during the work.
With the turbo out of the way, the stock exhaust system is removed completely. The factory rubber frame mounts are retained because they will be reused to support the new exhaust. Penetrating lubricant is applied to the hanger pins to help preserve the rubber mounts and make removal easier.
Banks addresses turbo performance by replacing the stock turbine housing with a larger, lower-backpressure housing and pairing it with a better-matched actuator. According to the explanation in the video, this combination helps boost come on quicker and stay on longer.
To perform the upgrade, the turbocharger is secured in a vise. The bolts are removed, and the center bearing and compressor assembly are separated from the original turbine housing. Those components are then installed into the new Banks turbine housing. Rather than replacing the entire turbocharger assembly, this approach modifies the existing unit to improve exhaust flow and turbo response.
The exhaust system is another major restriction point addressed by the kit. The stock Cummins exhaust uses a 3-inch pipe, which is already fairly large by typical pickup standards, but the Banks replacement increases that to a 4-inch stainless steel system. The kit also includes a Dynaflow muffler.
Installation starts with a new outlet pipe at the turbo, followed by a loosely fitted 4-inch clamp so the intermediate pipe can be positioned. For extended-cab trucks, Banks includes an extension pipe as part of the package. The muffler is then installed using special hanger clamps that fit into the factory rubber mounts. The system is completed with a tailpipe that routes over the rear axle and a stainless steel tip. Once everything is aligned properly, the clamps are tightened.
The build notes that no catalytic converter is used on this diesel application because one is not required here. The emphasis is on reducing backpressure and improving exhaust flow to support the upgraded turbo and increased fueling.
The kit includes a thermocouple to monitor exhaust gas temperature before the turbocharger. It mounts in the rear exhaust port so it can measure the temperature of the gases entering the turbo.
To install it, a small rag is stuffed into the exhaust passage to prevent metal shavings from entering the manifold while drilling and tapping the hole. After the hole is prepared, the thermocouple is threaded into place. This sensor becomes part of the monitoring package that allows the driver to keep track of how the upgraded diesel is operating under load.
The video pauses briefly to explain how a turbocharger works. Unlike a belt-driven supercharger, which is powered mechanically by the crankshaft, a turbocharger is driven by exhaust energy. Exhaust gas leaves the manifold and enters the turbine housing, where it spins the turbine wheel before continuing out through the exhaust system.
That turbine is connected by a shaft to a compressor wheel on the intake side. The compressor acts like a centrifugal supercharger: it draws in fresh air, compresses it, and sends it through the outlet tube, then through the intercooler, and eventually into the intake. This explanation ties directly into the modifications already made, since both the freer-flowing exhaust and the revised turbine housing are intended to improve the turbo's ability to move air.
After the turbo and exhaust upgrades, attention turns to the electronic side of the package. Banks includes a high-flow inlet tube and an AutoMind computer, along with the necessary wiring, gauges, and a gauge pod. The stock inlet is removed because it is considered restrictive, and the new wiring harness is routed underneath that area before the replacement inlet is installed. Three bolts are also removed so the throttle assembly can be shifted aside for wire access.
Inside the cab, the AutoMind module is mounted behind the lower dash panel beneath the steering column. On this truck, the trailer brake module has to be moved first to make room. The AutoMind is positioned between the plastic dash panel and the metal subpanel, but final mounting is delayed until all electrical connections are complete.
The wiring is presented as straightforward. A wire at the top of the fuel injection pump is spliced to accept the yellow lead from the Banks harness, and the harness is then routed through the firewall grommet into the cab. The main connector plugs into the AutoMind module. The system's purpose is to upgrade fuel delivery control so that fueling matches the increased airflow, with the stated goal of maximizing both power and efficiency.
Additional harness connections are made in line with the throttle position sensor and the MAP sensor on the intake. A ground is attached to a bolt under the hood, and the thermocouple wiring is connected so exhaust temperature can be monitored through the system.
To monitor the upgraded diesel, the kit uses a turbo boost gauge and an exhaust temperature gauge. In this installation, those gauges are mounted in an A-pillar pod rather than being integrated into the dash, which provides easy visibility without modifying the truck's interior panels. Once the pod is secured, the gauge wiring is routed to the back of the AutoMind and plugged in.
With the wiring complete, the last underhood step is installing the new air intake tube. The dipstick has to be relocated using the hardware supplied in the kit. The finished intake arrangement remains visually subtle; aside from the new inlet tube, the truck still looks largely stock under the hood until the throttle is opened and the added airflow and fueling come into play.
The finished truck is tested on the dyno to measure the effect of the Banks Power Pack. The result is a gain of about 108 horsepower and nearly 240 foot-pounds of torque over stock. Starting from roughly 180 horsepower and 410 foot-pounds, that represents a dramatic increase in usable diesel performance, especially for towing and hauling.
The video closes by noting Banks' claim of about 7 percent better fuel economy along with the power increase. It also mentions that similar kits are available for Ford Power Stroke and GM diesel applications. The overall conclusion is that the Power Pack improves the Cummins by addressing the complete airflow and fuel-delivery path: lower exhaust restriction, a revised turbo turbine housing, improved intake flow, electronic fuel control, and driver monitoring through boost and exhaust temperature gauges.