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F-150 Roush Supercharger Installation

Our quest to build the baddest truck to give away for our 2005 sweepstakes started with a stock 4x4 Crew Cab F150. First, we lifted the truck with a Pro-comp suspension lift system. Then we dressed up the exterior with Roush truck accessories, huge fender flares, and big off-road wheels and tires. This thing was big and intimidating. But we didn’t want it to just be big; we wanted it to be fast! So, we contacted Roush, who hooked us up with 112 extra horsepower coming from its new F-150 supercharger kit.

The Roush Supercharger

The Roush unit is a Ford factory roots-type supercharger and is the same package that can be found on the Ford Lightning truck. With a standard setting of 6 PSI, this baby will add up to 112 horsepower to your F-150, turning it from a timid turtle to a screaming monster. And, it’s authorized by Ford, so it won’t void your factory warranty!

The Installation

Use Proper Tools - Torque Wrench
This is a torque wrench. Make sure you use the proper tools when doing this installation.
Read The Instructions
Pay Attention To The Instructions
Note: This installation article is not a substitute for the instructions supplied with your kit. Please follow all safety instructions recommended by the manufacturer.

The Roush supercharger is available for the 2004-2006 Ford F150 and comes with all instructions and hardware required for installation. The instructions include a complete list of all tools required, as well as pictures of each step in the installation process. Follow them to a "T".

For better access to the engine compartment and for better lighting, we removed the hood and headlights prior to installation. Enough talk, let's check out the installation.

Section A: Disassembly

Grille Shell Kit Diagram
1. For safety reasons, disconnect the negative battery terminal.
Grille Shell Kit Diagram
2. Unbolt the PCM (Powertrain Control Module) and remove it from the vehicle. It will be shipped to Roush for reprogramming.
Grille Shell Kit Diagram
3. After removing the stock air intake tube and air cleaner, remove the radiator cover.
Grille Shell Kit Diagram
4. After draining the radiator, remove the upper radiator hose as well as the radiator hose support bracket.
Use Proper Tools - Torque Wrench
5. Using a fan removal tool, disconnect the fan from the water pump.
Pay Attention To The Instructions
6. Once the fan is removed, you can then unbolt the fan shroud from the radiator.
Read The Instructions
7. After disabling the belt tensioner, you can remove the alternator and the alternator support bracket.
Grille Shell Kit Diagram
8. Remove the heater hose from the water crossover located behind and to the passenger side of the alternator.
Grille Shell Kit Diagram
9. After disconnecting the TPS (Throttle Position Sensor) and ETC (Electronic Throttle Control) from the throttle body, it is removed from the intake.
Grille Shell Kit Diagram
10. Double check that the battery is disconnected and separate the fuel line from the fuel rail. Wrapping the connection in rags prior to separation is recommended.
Grille Shell Kit Diagram
11. After removing the IPS (Injector Pressure Sensor) and ground strap from the fuel rail and the wiring connectors on the injectors, unbolt and remove the fuel rail.
Grille Shell Kit Diagram
12. After removing the 10 intake manifold bolts and lifting the manifold slightly (without removing it), remove the water crossover.
Grille Shell Kit Diagram
13. After disconnecting the brake booster, remove the factory intake manifold.
Grille Shell Kit Diagram
14. Remove the wiring harness from the back of the stock intake manifold. It will be installed onto the new Roush intake manifold.

Section B: Modifications

Grille Shell Kit Diagram
15. To accomodate the supercharger drive belt and pulleys, 31mm must be trimmed from the fan shroud.

Grille Shell Kit Diagram
16. After trimming the fan shroud, smooth any rough edges with a sander or file.

Grille Shell Kit Diagram
17. Install the intake wiring harness, along with the new boost solenoid, onto the back of the new Roush intake manifold.
Grille Shell Kit Diagram
18. Insert the supplied crush limiters into the intake manifold gaskets.
Grille Shell Kit Diagram
This is Jimmy, Stylin' Trucks' videographer. He directed the Roush Installation Video
Grille Shell Kit Diagram
19. Install the throttle body spacer, along with the supplied gasket, onto the supercharger.
Grille Shell Kit Diagram
20. Install your factory throttle body to the throttle body spacer. Use the same O-ring gasket that was on your factory intake manifold.
Grille Shell Kit Diagram
21. In order to clear the front casing of the supercharger, the green plastic adaptor must be removed from the alternator.

Grille Shell Kit Diagram

22. It's now time to begin the wiring required for installation of the Roush Supercharger. Though it's too complicated to go over here, the wiring is basic and straight-forward, and the detailed instructions make it quite easy.
Use Proper Tools - Torque Wrench
23. Using the supplied hardware and pieces, assemble the new Roush airbox.
[Editor's note: Staring seductively into the camera is a rookie move and should be avoided at all costs.]
Pay Attention To The Instructions
24. Install the factory mass airflow sensor into the new Roush intake tube.

Section C: Installation

Grille Shell Kit Diagram
25. After confirming that your intake manifold gaskets are in place, put the intake manifold down onto motor.
Grille Shell Kit Diagram
26. After installing the water crossover, tighten the intake manifold bolts down in order.
Grille Shell Kit Diagram
27. Install the fuel rail onto the new intake manifold after lubricating the injector O-rings. Then bolt it down.
Grille Shell Kit Diagram
28. Now it's time to install the Roush supercharger assembly. Be sure to line up the bolt holes and lower the supercharger straight down.
Grille Shell Kit Diagram
29. Install the modified alternator back onto the engine.
Grille Shell Kit Diagram
30. Using a breaker bar, loosen the tensioner and install the serpentine belt.
Grille Shell Kit Diagram
31. Once the crank pulley adaptor is installed, install the Roush supercharger drive pulley and bracket.
Grille Shell Kit Diagram
32. Install the front bridge. This includes the new belt tensioner for the Roush supercharger drive pulley.
Grille Shell Kit Diagram
33. After installing the fan adaptor, you can now install the fan and fan shroud.
Grille Shell Kit Diagram
34. Before installing the new Roush radiator hose, use a breaker bar and install the Roush supercharger drive belt.
Grille Shell Kit Diagram
35. Once you have made the appropriate intake system connections, you can install the new Roush airbox.
Grille Shell Kit Diagram
36. Install the new Roush intake tube between the Roush airbox and the factory throttle body, now located on top of the Roush supercharger.
Grille Shell Kit Diagram
37. Install the new high-flow air filter.
Grille Shell Kit Diagram
38. Reconnect your battery. Now is the time to double check all of your clamps and bolts.
Grille Shell Kit Diagram
That completes the installation of the Roush supercharger onto our sweepstakes F-150.

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Related Links


  • Roush Performance Products
  • Roush Supercharger Installation Video
  • Truck Accessories
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