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How to Install Roush Power Pac - Level 1 on your F-150

Installation Time

1 hours

Tools Required
  • Metric 1/4" Drive Socket Set
  • Flat-head Screwdriver
  • Trim Tool

SECTION A – REMOVAL

The following section will guide you through the removal of the stock components. Special care should be taken to label fasteners and parts that are taken off during this procedure since many will be reused.

1. Cover both fenders with fender covers to protect the vehicle fi nish.

2. Disconnect the battery ground cable.

3. Remove the bolt retaining the stock air box to the inner driver side fender. Retain the bolt, sleeve and grommet for later use.


4. Loosen the hose clamps retaining the clean air tube to the throttle body and air box lid.


5. Disconnect the two (2) quick connect fi ttings from the clean air tube.


6. Release the two (2) clamps on the front of the air box.


7. Remove the air box lid.


8. Remove the clean air tube from the vehicle.


9. Remove the two (2) push clips retaining the dirty air inlet duct to the grill closeout.


10. Remove the lower air box and dirty air duct from the vehicle.


11. Remove the self-tapping screw retaining the dirty air inlet onto the lower air box.


12. Remove the dirty air inlet from the lower air box.

13. If necessary, remove the two (2) rubber grommets from the bottom of the air box and reinstall them into the tray below the air box.


SECTION B — INSTALLATION

1. Insert the dirty air inlet into the Roush air box (P/N: 1115-9A612). Reuse the self-tapping screw that was removed earlier. Tighten to 3 Nm.


2. Reinstall the bolt, grommet and sleeve into the driver side fender. Tighten the bolt to 17.5 Nm.


3. Install the Roush air box (P/N: 1115-9A612) into the vehicle by locating the two (2) bosses on the bottom of the box while aligned to the grommet.


4. Install the air fi lter (P/N: 131550-9601R) onto the fi lter tube (P/N: 111550-12B579) and tighten the clamp to 3 Nm. Make sure the fi lter is installed (as shown) with the metal rib down.


5. Slide the fi lter and tube assembly into the air box.


6. Install the two (2) M8 bolts (P/N: W500224-S437) and tighten to 10 Nm.


7. Install the rubber grommet (P/N: 1150-58GRMT) and fi ttings into the clean air tube. You will want to use soapy water or glass cleaner to aid the installation (fi ttings: left P/N: 1311-9N285, right P/N: KLR-9N285).


8. Install couplers and clamps onto the clean air tube (P/N: 111550-9B660) as shown. Tighten the clamps retaining the coupler to the tube to 3 Nm. Leave outside two (2) clamps loose (couplers: right P/N: 111550-9B662, left P/N: 111550- 9B662) (clamps: right P/N: R07130015-13, left P/N: 308707426).


9. Install the clean air tube assembly between the throttle body and the air box. Tighten the clamps to 3 Nm.


10. Attach the two (2) quick connect hoses to the mating barbs on the clean air tube.


11. Reinstall the two (2) push pins into the dirty air inlet.


12. Insert the seal fi ller (P/N: 1115-9B624FOAM) halfway into the air box seal (P/N: 1115-9B624) as shown.


13. Install the air box seal starting in the location shown. You may need to trim the seal to the correct length. (Note: Start the seal at the middle of the inlet tube.)


14. The installation is now complete.


PCM FLASHING

Proceed with steps 1-2 if you have a SAE J2534 pass through device (e.g. Puma, VCM I, VCM II)

If you do not have a SAE J2534 device visit your local Roush Dealer or Performance Shop with the appropriate tools for PCM Calibration.

1. If equipped with a SAE J2534 pass through device, refer to the RDT-CALIM manual found on our website. http://rdt.roush.com The RDTCALIM manual will guide you through the ROUSH Diagnostic Tool (RDT) software installation process and the ROUSH PCM fl ashing procedure detailed in RDT-CALIM.

2. Once the PCM has been successfully recalibrated, start the engine and check for unusual noises, dash service lights, and unusual operation. If problems are detected, immediately stop the engine or vehicle, diagnose and repair the problem.