How to Install Roush Cold Air Intake on your F-150

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 finish.

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

5. Slide the filter 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 fittings into the clean air tube. You will want to use soapy water or glass cleaner to aid the installation (fittings: 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 filler (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.