(approx) 1 Hour
Simple installation for anyone.
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Justin: The Roush Level 1 Power Pac will be a great way for the S550 GT owners out there to add upwards of 25 horsepower and 30 pound-feet of torque, according to Roush, using two extremely basic parts – their cold air intake system along with the included calibration and dongle, both of which are gonna be 50-state legal and can be had for right around $800. Now, that calibration will be optimized for 91 octane fuel or higher but can still be used with lesser octanes if needed, although, expect those gains to suffer slightly as your octane levels drop. Finally, interested buyers can also take advantage of Roush's optional 3-year, 36,000-mile powertrain warranty with this particular Power Pac and calibration, and that's something you're not always gonna see in the land of aftermarket tuning. The install is gonna be extremely straightforward for both the intake and the calibration. So let's call it a strong one out of three wrenches on the difficulty meter here, with a detailed walkthrough to come later in the video. But first and foremost, let's talk dyno numbers. Baseline runs using our automatic GT gave us 358 horsepower and 348 pound-feet of torque to the rear wheels. With the Roush Level 1 Performance Pac installed, the car is now making 384 horsepower and 373 pound-feet of torque to the rear wheels. Now, that's good for a peak gain of 26 horsepower over our baseline numbers and gains of as much as 31 horsepower and 27 pound-feet of torque under the curve. But now that you have a better idea of what kinda gains you might be able to expect on your own GT at home, let's break down how it's all made possible. And at first glance, guys, this is gonna be a very basic or simple kit. One-half of your Power Pac will be the Roush cold air intake system you see here. No doubt, a solid piece that's gonna replace your factory airbox along with that cheap paper element factory filter with the reusable high-flow dry option you see right here. Now, the Roush filter is not only going to be an improvement in both filtration and also appearance, let's be honest, but it's also going to be an improvement in power as well, thanks to less intake restriction. Now, that's gonna result in that small bump in power we just talked about, along with some other benefits as well. That includes a little bit better at throttle response, maybe the slightest increase in fuel economy, of course, if you can stay off the pedal a little bit, and also a nice little bump in sound coming from under the hood of that Coyote engine, thanks to the open element design. Now, from a construction standpoint, the Roush is gonna offer OEM levels of fit and finish, and I think that's one of the big reasons why this particular option is so popular in the category. A lot of guys like to retain that OEM-style look under the hood. And if that's the case, then the Roush will certainly be for you. Injection-molded plastic will be making up most of the materials here, while the intake filter itself, again, will be dry. It is washable and reusable, and will not require any reoiling, which is something some owners might prefer. Last but not least, you have the Roush calibration along with the included dongle. And I really like the fact that they started including these dongles with their Power Pacs. It's something they've started doing recently here. And it's nice because, before, you had to take the voucher to your dealer, have them flash that to your ride, and not a big deal but it did add an extra layer of inconvenience. That's not gonna be the case anymore here. As long as you have a laptop along with the dongle and the tuning voucher, you should be able to get this thing uploaded to your ride. Now, I'll be completely honest here, guys. The dongle really isn't gonna be anything more than a vessel for the calibration. However, the RDT software will allow you to do some cool stuff like read and clear those "Check Engine" lights, reset your KAM, or your keep-alive memory, and will even allow you to data log using your laptop. So yes, while the physical device really isn't terribly impressive, the software certainly is the star here. But once that calibration has been flashed to your Mustang, you can expect the advertised gains we talked about earlier, and even experienced with our shop car here at AM, again, on at least 91 octane. As I did point out earlier, you certainly can use 87 or 89, but expect reduced power with those lower octane levels. And how are those gains made possible through the calibration? Well, you're gonna be looking at improved camshaft timing, along with a big-time focus on your throttle mapping to give the car a slightly sportier or snappier feel overall. And as I did point out earlier, if you did want to opt for the 3-year, 36,000-mile warranty, you have that option. But you have to apply for that with Roush directly, and it must be done so within 30 days of your installation. Now, if you like the idea of these assembled Power Pacs, but you craved a little bit more power and maybe even a little bit more sound, be sure to check out the Level 2 Power Pac here from Roush, also available on the site. Of course, you're gonna look at a little bit more horsepower and torque with the kit. But more importantly, you're gonna be making a whole lot more sound, thanks to the included fan favorite Roush axle-back that is paired up with the intake and calibration in that Level 2 kit. Well, let's switch gears and talk about the installation a little bit more here, guys. And I did go one out of three wrenches on the difficulty meter, maybe a strong one out of three because of the combination. And to give you a better idea of what your day will look like in the garage or driveway, here is a detailed walkthrough along with a tool breakdown. Travis: All right. So the first step of our Power Pac install is removing our stock air assembly. Now, to do this, you're just gonna need to start off with a flat-head screwdriver. We're gonna disconnect our MAF sensor, we're gonna disconnect this clamp tightening down the top of the airbox, and we're gonna loosen these two clamps that hold the airbox to the vehicle. So with the top airbox removed, the next step is removing the filter itself, as well as the bottom airbox. Now, our car has been worked on quite a lot, so we're missing our screw that holds this down. Normally, you would loosen this, and you can pull the whole assembly out of the vehicle. All right. Now that we have our airbox assembly removed from the vehicle, the next step is removing the air intake tub itself. Normally, you would have to remove your sound tube which pumps sound into the cabin. We didn't like that, so we already took ours off. So the next steps are gonna be removing your PCV hose, right here, and this breather hose, as well as removing the final clamp that secures the tube to the actual throttle body itself. Okay, guys. Now, that we have our stock airbox assembly out of the vehicle, it's time for us to do some out-of-car assembly with our new air system. Now, I'm gonna walk you through each step here. You can also go on Roush's site and get some nice printed and color instructions if you don't wanna keep rewinding and listening to me the whole time. However, I'm gonna walk you through anyway. First things first, we're gonna reuse some of the rubber grommets from our stock airbox assembly. So you're gonna start with pulling this little rubber grommet off the bottom of the stock airbox, and we're gonna move it over to our new one. The second piece we're reusing from our stock airbox assembly is this other little rubber grommet. This is an actual little isolator, and that's gonna sit on the inside of the fender well on your new airbox assembly. Now, with those two parts reused on the new airbox assembly, you can go ahead and discard your old one. All right. The next piece is putting on our weather stripping here. It's got these nice little plastic divots, and you're just gonna pop those inside these little rivet holes on the top of the airbox assembly. All right. So with your weather stripping installed, the last piece is installing this little breather tube. This is what actually pulls in cold air from the front of the vehicle to the air assembly. All right. So now that we have our airbox assembly actually assembled, we're gonna go ahead and put this in the vehicle. Once this is in the vehicle, we can actually put our cold air intake itself inside the airbox assembly. So now that our new airbox assembly is all put together, we're actually gonna assemble the air intake itself, and I'm talking about the filter and the tubing for the mass airflow sensor. First things first, you're gonna put these two together with the provided clamp. All right. Now that we have our air intake attached to the MAF housing, we're actually gonna go ahead and switch over our mass airflow sensor from the stock MAF housing to the new one. And that's just a little Allen key head. Okay. Now that we have our mass airflow sensor installed in our new mass airflow housing, we're gonna go ahead and install this in our new air assembly. Now, you wanna make sure that the mass airflow sensor is facing towards you and towards the front of the air assembly so that the plug has space to plug in once you install it. All right. Once you have those two bolts hand-threaded for the filter itself, you're gonna go ahead and tighten those down using a 10-millimeter socket and an extension. So now that we have our mass airflow sensor, our air filter, and our airbox assembly all put together as one piece, we're gonna go ahead and install this in the vehicle. We're not gonna put the tube on yet. We wanna have some room once this is in the vehicle so that we can move this around, play with it a bit, and get everything seated. Then, we'll tighten everything down. Now, before you install the intake filter and the airbox assembly, you wanna make sure that your air inlet lines up with the hole that's down here, hidden behind the front grille. You also wanna make sure that your mass airflow sensor has enough slack so you can plug it in once you put this all together. Now that our air filter and our airbox is all connected, we're gonna go ahead and do the last step. And that's actually installing the new air intake tube, as well as all the plumbing on all these connections. All right. So with those dyno runs, you saw we did make some pretty good curve and peak gains, as my buddy, Justin, mentioned earlier. And with that said, that actually wraps up our review and install of the Roush Power Pac for your '15 and up Mustang GT. I'm Travis. Thanks for watching. And for all things Mustang, keep it right here at americanmuscle.com.
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(approx) 1 Hour
Simple installation for anyone.
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