Install Instructions for 75-5040

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Before You Start

  • Please read the entire product guide before proceeding.
  • Ensure all parts are present.
  • If you are missing any of the components, call our customer support at (909) 947-0015.
  • Do not work on your vehicle while the engine is hot.
  • Make sure the engine is turned off and the vehicle is in Park or the Parking Brake is set.
  • Note: This intake kit may not fit with the following Aftermarket Parts installed: Body Lift or Lowering Kit, Custom Hood, Throttle Body Upgrade

Required Tools

  • 8mm, 10mm, 13mm Wrench & Socket
  • 7/16” Wrench and Socket
  • 5/16” Nut Driver or Flat Blade Screwdriver
  • Phillips Screwdriver

STEP 1

With the ignition switched off and the parking brake set, disconnect the negative battery cable on the driver’s side.

IMPORTANT: Failure to disconnect the battery for a minimum of 2 hours may cause the Check Engine Light to illuminate upon completion of the installation or subsequent operation.

DO NOT SKIP THIS STEP!

STEP 2

Loosen the hose clamp connecting the tube to the airbox and the clamp attaching the tube to the resonator body. Then move the intake tube from the truck.


STEP 3

Loosen the two screws on the resonator assembly using a 10mm socket. Disconnect the Temp. Sensor wiring harness from the sensor.


STEP 4

Remove the OE throttle body gasket.


STEP 5

2004-08 Models: Remove the breather hose from the lid of the airbox only.


2003 Models: Remove the breather hose from the oil fill reservoir.

STEP 6

Remove the airbox by carefully pulling the air box straight up out of the four pins of the airbox tray. Then remove the two bolts mounting the tray to the frame using a 13mm socket.


STEP 7

Remove the eight screws securing the wheel liner using an 8mm socket.


STEP 8

From inside the engine compartment, carefully pull the wiring harness connector out from the wheel liner. Then remove the wheel liner from the truck.


STEP 9

Using a 13mm socket, remove the other 2 bolts securing the airbox tray. Then remove the tray from the truck


STEP 10

Insert the supplied Grommet (D) into the Airbox (M).


STEP 11

For those concerned about minimal engine heat; insert the Air Inlet Plug (T) into the end of the Air Inlet Tube (S). Attach using the supplied 1/4”-20x3/4” Screws (V), 1/4” Lock Washers (U) and 1/4” Flat Washers (W). For those seeking additional air flow, set the Air Inlet Plug aside and save all the supplied hardware.


STEP 11 (IMAGE 2)

STEP 12

Carefully place the Airbox (M) and the Air Inlet Tube (S) in the general location. You may have gently push some hoses aside to drop both parts in at the same time.


STEP 13

Using the OE bolt, secure the Airbox (M) to the frame. Leave loose for now.


STEP 14

From inside the wheel well, attach the airbox to frame using the supplied M8x40mm Hex Bolt (K) and Fender Washer (L). Then secure both bolts mounting the airbox to the frame.


STEP 15

Insert the Air Inlet Tube (S) onto the Airbox (M) and secure using the supplied 1/4”-20x3/4” Screws (V), 1/4” Lock Washers (U) and 1/4” Flat Washers (W).


STEP 16

Reinstall the wheel liner using 6 of the OE screws. Reinstall wiring harness connector into wheel liner that was removed in Step #8.


STEP 17

Secure the wheel liner to the airbox using two supplied 1/4”-20x3/4” Screws (V) and Flat Washers (W) inside the airbox. Use the 1/4” Nylock Nuts (X) and 1/4” Flat Washers (W) under the wheel liner.


STEP 18

Insert the S&B Filter (J) onto the Adapter Tube (H) and secure the #104 Hose Clamp (I). Install the assembly into the Airbox.

2004-08 Models: Push the OE breather hose onto the stem of the Adapter Tube (H).

STEP 19

2003 Models Only: Install the S&B Breather Hose (Z) onto the oil fill reservoir using the #8 Hose Clamp (Y) and push the other end onto the stem of the Adapter Tube (H). Secure using the supplied Cable Tie (AA).


STEP 20

Install the Clear Lid (N) using the supplied 5/16” SS Screws (Q) and Rubber Washers (R) along with the 10-24 Screws (P) and SS Sealing Washers (O). This will secure the Filter Adapter to the Airbox as well. (Do not over tighten!)


STEP 21

Note the OE Temp. Sensor orientation. Then carefully turn it counterclockwise and pull it out of the OE resonator. Then remove the O-ring from the sensor.


STEP 22

Insert the supplied Grommet (D) into the Intake Tube (E). Carefully push the Temp. sensor into the grommet using a twisting motion. Be sure to match the OE orientation.


STEP 23

Place a #72 Hose Clamp (F) over each end of the Hump Coupler (G). Then slide the hump coupler over the end of the Intake Tube (E).


STEP 24

Secure the Silicone Step Coupler (B) to the throttle body using a #56 Hose Clamp (A). Place the #60 Hose Clamp (C) around the top of the Silicone coupler.


STEP 25

Insert the Intake tube assembly into the Silicone Coupler, then slide the Hump Adapter over the Adapter Tube. Tighten all hose clamps when you are satisfied with the positioning.


STEP 26

Reconnect the Temp. Sensor wiring harness.


STEP 27

Reconnect the battery. Inspect your installation, make sure the kit is properly positioned and all fasteners are secure. Affix the CARB sticker (if applicable) near the intake kit. The installation is now complete.