Ford F Series Air Box Modification

Ford F series model year 2011 trucks have plastic air box assemblies. It has been discovered that a plastic tab on the back side of the air box lid can be broken off during daily inspections of the air filter during removal and reassembly of the air box to access the filter. In the event this tab breaks off, it may fall into the air box and lay on top of the air filter. If the engine is then started, the tab will be pulled into the turbo system and cause catastrophic damage resulting in expense repair costs; the turbo has to be replaced. This document will describe the process to safely remove the tab. The tab is not a necessary component of the air box assembly.

F-Series Air Box Modification Plastic tab which can break off and cause damage to the turbo.

F-Series Air Box Modification Locate the air box assembly on the passenger side of the vehicle, forward of the primary battery, under the hood.

F-Series Air Box Modification Remove the electrical connector on top of the air box by sliding the red tab back first, this will unlock the plug.

F-Series Air Box Modification Remove the electrical connector from the receptacle.

F-Series Air Box Modification Remove the wire tie clip from the air box assembly. This clip is located next to the air filter restriction indicator.

F-Series Air Box Modification The air box assembly has four spring clips which hold the lid in place. They are located on the front side of the assembly. Disengage the four clips.

F-Series Air Box Modification Loosen the clamp for the fresh air intake hose at the air box assembly.

F-Series Air Box Modification The air box lid has four heavy duty tabs which slide into groves on the back of the assembly, opposite of the spring clamps. Slightly raise the air box at the front and slide it forward to remove.

F-Series Air Box Modification Remove the air box lid from the fresh air intake hose.

F-Series Air Box Modification Once the air box lid has been removed, locate the plastic tab to be removed. The tab is located where the fresh air intake hose attaches to the lid.

F-Series Air Box Modification Remove the tab by using a pair of end nippers. Snip the tab off flush with the air box lid housing.

F-Series Air Box Modification Tab removed, flush with air box lid. You may use a flat file or small plainer to remove any residual plastic and give it a clean, professional appearance. Once removed, you may re-assemble the air box.

F-Series Air Box Modification Re-assembly should be in reverse order of disassembly. Assemble air box lid and fresh air intake hose; ensure the grove on the lid and on the hose are properly aligned. Align the heavy duty tabs on the lid with the slots on the lower assembly.

F-Series Air Box Modification Once you have the air box lid back in place, engage the four spring clips. Ensure you haven’t pinched any wiring between the lid and the lower assembly. Re-assemble the electrical connector and receptacle, slid the red tab back in to lock the connector to the receptacle.

F-Series Air Box Modification Re-attach the wire tie clip to the air box lid.Tighten the fresh air intake hose clamp.

F-Series Air Box Modification Congratulations, you have successfully completed the air box modification.