Banjo Bolt Mod - PowerStrokeNation : Ford Powerstroke Diesel Forum
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post #1 of 14 (permalink) Old 07-18-2010, 01:22 AM Thread Starter
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Banjo Bolt Mod

Well today I drilled out my stock banjo bolts and i have read alot of posts on it but not many had pics of it, so I took pics to show you step by step as I did it.

I have the back half of the fan shroud deleted so it was Alot easier for me to get to the bolts. The Passenger side is VERY easy to get to. The drives side is a PITA as you can see in the pics

A flex head gear wrench works great for the divers side bolt to get behind the rad. hose

Once the bolts were out I removed the guts As you can see in the pic

I then drilled the center out to 1/4 inch and the sides to 1/8 I also added another hole to help a little more I also used the 1/4 bit to take the edge off the 1/8 holes



I put it all together and it didn't leak so it must have worked
It took a bit to get it all done but it was a pretty easy job to do and I saved the $ 13 some bucks for the 6.4 bolts and I did a BB fuel shim mod at the same time also that I will post later.

2003 F-350 Crew 4x4 205k 4" silverline turbo back CAI, Garret Stage One VGT, 165cc injectors, SCT ID's x-race x-street tow
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post #2 of 14 (permalink) Old 07-18-2010, 02:35 AM
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Re: Banjo Bolt Mod

Did you notice a difference after you did both?
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post #3 of 14 (permalink) Old 07-18-2010, 11:13 PM Thread Starter
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Re: Banjo Bolt Mod

Yeah It is alittle more responsive and it hazes a little more on the top end.

2003 F-350 Crew 4x4 205k 4" silverline turbo back CAI, Garret Stage One VGT, 165cc injectors, SCT ID's x-race x-street tow
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post #4 of 14 (permalink) Old 07-19-2010, 01:07 AM
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Re: Banjo Bolt Mod

Worth it then considering the price, I just bought the FPR kit from ford cause at the time I didnt have a fuel pressure gauge.....new bolts will be coming soon though also.
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post #5 of 14 (permalink) Old 07-19-2010, 01:36 AM
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Re: Banjo Bolt Mod

Do you have the part number for that kit?

2005 f250 fx4 lariat
egr delete, head studs, edge cts
mbrp 4" straight pipe. sct tuned by eric
future mods..
190 casserly injectors
garret powermax,

looking for some 190s pm if you have some
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post #6 of 14 (permalink) Old 07-19-2010, 03:36 AM
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Re: Banjo Bolt Mod

Only problem your gonna have with that is getting that bolt out without breaking it. This mod has been around for years and years. Another thing people quit doing for a reason. Not trying to rain on your parade, but you can only take so much out before it gets too weak.


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post #7 of 14 (permalink) Old 07-19-2010, 04:05 AM
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Re: Banjo Bolt Mod

I did this on my truck, didn't notice a single difference. Good peace of mind though.

Also, I always like to mention for those of us with dual alternators, the passenger side is a LOT harder than the drivers side.

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post #8 of 14 (permalink) Old 07-20-2010, 01:31 AM Thread Starter
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Re: Banjo Bolt Mod

dalpilot yeah I was worried about twisting it off but the 1/8 inch bit didn't take much out. I also only drilled 1 extra hole but yes I could see it breaking if you cranked it in there which I did take it easy tightening it down.

2003 F-350 Crew 4x4 205k 4" silverline turbo back CAI, Garret Stage One VGT, 165cc injectors, SCT ID's x-race x-street tow
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post #9 of 14 (permalink) Old 10-21-2010, 05:04 PM
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Re: Banjo Bolt Mod

I'd like to know more about the FPR kit from ford .


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2005 CCSB
Cheap parts removed
Expensive parts installed
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post #10 of 14 (permalink) Old 10-21-2010, 05:39 PM
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Re: Banjo Bolt Mod

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Originally Posted by kenny7231 View Post
Do you have the part number for that kit?

Banjo fitting; 1834731c1
washer: 1828336c1

Keep in mind that you need two washers per bolt and you have to use new, not reuse the old ones.

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