I would appreciated any information anyone could give me on this subject. I have seen several 5.9 cummins 190hp described with a banks power pak or upgrade. Approximately what does this add to the 5.9 or is this what gets it from 160hp to 190hp..also how does this approach the limitations of the 4 speed allison 500 series tranny... I was interested in the 92-94 models...thanks

First the 5.9 can be pushed to 400 hp with little trouble.

The 500 series Allison is maxed out at about 230hp.

My '92 Breakaway is pushing 300hp. Was higher but I backed it down. Was pushing 370 and I was afraid of breaking stuff, but it sure was fun for a while.

I should add that I also changed the 542 to an allison 2000 5 speed.

I have the banks turbo and intake manifold. In addition I changed the fuel plate (another cummings part). At this time I opened the pumb all the way but still could not squirt enough juice thru the small injectors. So the final step was to change the injectors. Last I had to reset the pumb back down for reduce the new HP.

The transmission change is documented in the upgrade section.

Thanks Gary... from what I have seen on the Banks website (if I am interpretting it correctly)is that the stinger/power pak system will take the 5.9 to about 230-240 hp which is really is the max for the 4speed 500 allison series. I am not clear as to whether the test was for a standard 160 or 190 hp motor. My concern, as you suggested, is getting to many hp's for the tranny. If you put 70hp on a 160hp you got your max of 230 but if you put 70hp on 190 your at 260hp which, I would think, test the limits of the Allison tranny.