2015-2016 F-150 3.

5L Ecoboost V6
2015-2017 F-150 2.7L Ecoboost V6
Performance Pack Level 2
Installation Instructions
P/N: 422007 (1115TT-PWRPK2)

39555 Schoolcraft Rd, Plymouth MI, 48170 | 800.59.ROUSH

2015-2016 F-150 3.5L Ecoboost V6, 2015-2017 F-150
2.7L Ecoboost V6 – Performance Pack Level 2

2015-2016 F-150 3.5L

Ecoboost V6
2015-2017 F-150 2.7L
Ecoboost V6
Performance Pack Level 2
Installation Instructions
P/N: 422007 (1115TT-PWRPK2)

Application: 2015-2016 Ford F-150 3.5L Ecoboost V6, 2015-2017 Ford F-150 2.7L Ecoboost V6
Important Note:
Before installing the ROUSH Performance Product, please read through the installation procedure and verify that
all items are present. If you are missing hardware or have any questions, please contact ROUSH Performance at
1-800-59-ROUSH, 9:00 AM to 5:00 PM EST.

1115TT-PWRPK2 07252017 1 800.59.ROUSH

 2015-2016 F-150 3.5L Ecoboost V6, 2015-2017 F-150
2.7L Ecoboost V6 – Performance Pack Level 2

TABLE OF CONTENTS
Packing List for F-150 3.5L Ecoboost V6, F-150 2.7L Ecoboost V6 ........................................................................3
Equipment and Supplies Required............................................................................................................................3
Limit of Liability Statement ........................................................................................................................................3
Safety Precautions ....................................................................................................................................................4
Work Safely! ..............................................................................................................................................................4
Section A – Removal .................................................................................................................................................5
Section B — Installation ............................................................................................................................................7
PCM Flashing ..........................................................................................................................................................11
2015+ Ford F-150 Off-Road Exhaust Kit ................................................................................................................13
Packing List for 2015+ Ford F-150 Off-Road Exhaust Kit ......................................................................................14
Equipment and Supplies Required..........................................................................................................................14
Limit of Liability Statement ......................................................................................................................................15
Safety Precautions ..................................................................................................................................................15
Work Safely! ............................................................................................................................................................15
Section A – Disassembly .........................................................................................................................................16
Section B – Assembly .............................................................................................................................................16
Cut Lengths Per Wheelbase....................................................................................................................................18

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2015-2016 F-150 3.5L Ecoboost V6, 2015-2017 F-150
2.7L Ecoboost V6 – Performance Pack Level 2

PACKING LIST FOR F-150 3.5L ECOBOOST V6, F-150 2.7L ECOBOOST V6
Description Part Number Quantity
Air Box 1115-9A612 1
Filter Tube 1115TT-12B579 1
Clean Air Tube 1115TT-9B660 1
Filter w/ Clamp 131550-9601R 1
Hardware Kit 1115TT-CAKHWK 1
Bolt (M8 x 1.25 x 25) W500224-S437 2
Seal – Bulb Seal 25 mm CTL 1115-9B624 1
Rubber Seal Solid Round 0.5 inches 1115-9B624FOAM 1
Coupler – Air Box to Tube 1115TT-9B661 1
Coupler – CAT to DR 1115TT-9B662 1
Coupler – CAT to PS 1115TT-9B663 1
Clamp (110-130 mm) R07130015-13 1
Clamp (100-120 mm) R07130028-13 3
Clamp (3-1/16" to 4") 308707426 2
Hardware Kit B (2017 3.5L Ecoboost Only) 1115TT-CAKHWKB 1
Harness IAT Jumper 1117-12A690 1
Air Box Tray Bracket 1117-9B611 1
Bolt (M6 x 1.0 x 16) W500013-S307 2
EO Sticker D41828-9A095EO-AA 1

EQUIPMENT AND SUPPLIES REQUIRED

• Metric 1/4" Drive Socket Set
• Flat-head Screwdriver
• Trim Tool
• Pliers
• Drill
• 17/64" Drill Bit
• Center Punch

If you are missing any items, please call us toll free at 1-800-59-ROUSH.

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 2015-2016 F-150 3.5L Ecoboost V6, 2015-2017 F-150
2.7L Ecoboost V6 – Performance Pack Level 2

LIMIT OF LIABILITY STATEMENT

The information contained in this publication was accurate and in effect at the time the publication was approved
for printing and is subject to change without notice or liability. ROUSH Performance Products (RPP) reserves the
right to revise the information presented herein or to discontinue the production of parts described at any time.

SAFETY PRECAUTIONS
STOP STOP
CAREFULLY READ THE IMPORTANT SAFETY PRECAUTIONS and WARNINGS BEFORE PROCEEDING
WITH THE INSTALLATION!
Appropriate disassembly, assembly methods and procedures are essential to ensure the personal safety of
the individual performing the kit installation. Improper installation due to the failure to correctly follow these
instructions could cause personal injury or death. Read each step of the installation manual carefully before
starting the installation.
• Always wear safety glasses for eye protection.
• Place ignition switch in the OFF position.
• Always apply the parking brake when working on a vehicle.
• Block the front and rear tire surface to prevent unexpected vehicle movement.
• If working with a lift, always consult vehicle manual for correct lifting specifications.
• Operate the engine only in well-ventilated areas to avoid exposure to carbon monoxide.
• Do not smoke or use flammable items near or around the fuel system.
• Use chemicals and cleaners in well-ventilated areas.
• Batteries produce explosive gases, which can cause personal injury. Therefore, do not allow flames, sparks or
flammable substances to come near the battery.
• Keeps hands and any other objects away from the radiator fan blades.
• Keep yourself and your clothing away from moving parts when the engine is running.
• Do not wear loose clothing or jewelry that can get caught in rotating parts or scratch surface finishes.
• Allow the engine, cooling system, brakes and exhaust to cool before working on a vehicle.

WORK SAFELY!
Perform this installation on a good clean level surface for maximum safety and with the engine turned off.

1115TT-PWRPK2 07252017 4 800.59.ROUSH

2015-2016 F-150 3.5L Ecoboost V6, 2015-2017 F-150
2.7L Ecoboost V6 – Performance Pack Level 2

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 finish.
2. Disconnect the battery ground cable.
3. Release both clips holding the lid on the air box.

6. Remove the IAT by twisting the sensor.

4. Loosen the clamp between the clean air tube and

the passenger side turbo inlet.

7. Remove the clean air tube and air box lid from the
vehicle.

5. Loosen the clamp between the clean air tube and

the driver side turbo inlet.

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 2015-2016 F-150 3.5L Ecoboost V6, 2015-2017 F-150
2.7L Ecoboost V6 – Performance Pack Level 2

8. Remove the bolt retaining the stock air box to the

inner driver side fender. Retain the bolt, sleeve
and grommet for later use.

11. Remove the self-tapping screw retaining the dirty

air inlet onto the lower air box.

9. Remove the two (2) push clips retaining the dirty

air inlet duct to the grill closeout.

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

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

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2015-2016 F-150 3.5L Ecoboost V6, 2015-2017 F-150
2.7L Ecoboost V6 – Performance Pack Level 2

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.

IMPORTANT: Do not remove the shown silencer

rings.

2015-2016 F-150 proceed to step 9.

3. Print out the template and make sure the
dimensions are correct. Cut out the template.

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 2015-2016 F-150 3.5L Ecoboost V6, 2015-2017 F-150
2.7L Ecoboost V6 – Performance Pack Level 2

4. Tape the template to the side of the air box. Use a

6. Mount the bracket (P/N: 117-9B611) to the
punch to mark the two (2) drill holes.
outside of the air box using two (2) M6 bolts
(P/N: W500013-S307). Torque to 10 Nm.

5. Drill the holes out using a 17/64” drill bit.

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2015-2016 F-150 3.5L Ecoboost V6, 2015-2017 F-150
2.7L Ecoboost V6 – Performance Pack Level 2

7. Install the Roush airbox into the truck by locating

the two (2) bosses on the bottom of the box while
aligned to the grommet.

8. 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.

10. Install the two (2) M8 bolts (P/N: W500224-S437)

and tighten to 10 Nm.

9. Slide the filter and tube assembly into the air box.
Twist the IAT sensor into the port as shown.
NOTE: 2017 F-150 use the IAT sensor jumper
harness (P/N: 117-12A690) to connect the IAT
sensor.

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 2015-2016 F-150 3.5L Ecoboost V6, 2015-2017 F-150
2.7L Ecoboost V6 – Performance Pack Level 2

11. Install couplers and clamps onto the clean air

tube (P/N: 1115TT-9B660) as shown. Tighten
the clamps retaining the coupler to the tube to
3 Nm. Leave the outside clamps loose (coupler:
top P/N: 1115TT-9B663, bottom P/N: 1115TT-
9B661, left P/N: 1115TT-9B662) (clamps: top P/N:
R07130028-13, bottom P/N: R07130015-13 and
P/N: R07130028-13, left P/N: 308707426).

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

12. Install the clean air tube assembly between the

throttle body and the air box. Tighten the clamps
to 3 Nm.

15. Insert the seal filler (P/N: 1115-9B624FOAM)

halfway into the air box seal (P/N: 1115-9B624) as
shown.

13. Clip the harness and vacuum line into position on

the air box bracket.

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2015-2016 F-150 3.5L Ecoboost V6, 2015-2017 F-150
2.7L Ecoboost V6 – Performance Pack Level 2

17. Place the EO sticker under the hood of your

vehicle on a clean, metal surface.
18. The installation is now complete.

16. Install the air box seal starting in the location

shown. You may need to trim your seal to the
correct length. (NOTE: Start the seal at the middle
of the inlet tube.)

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 RDT-
CALIM manual will guide you through the ROUSH
Diagnostic Tool (RDT) software installation
process and the ROUSH PCM flashing 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.

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 2015-2016 F-150 3.5L Ecoboost V6, 2015-2017 F-150
2.7L Ecoboost V6 – Performance Pack Level 2

168.3 mm
DIMENSIONS ARE
FOR PRINTING
REFERENCE ONLY.

82.6 mm

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2015-2016 F-150 3.5L Ecoboost V6, 2015-2017 F-150
2.7L Ecoboost V6 – Performance Pack Level 2

2015+ Ford F-150 Off-Road

Exhaust Kit
Installation Instructions
P/N: 1115-5E292ORR

Application: 2015+ Ford F-150 — OFF-ROAD USE ONLY

Important Note:
Before installing the ROUSH Performance Product, please read through the installation procedure and verify that
all items are present. If you are missing hardware or have any questions, please contact ROUSH Performance at
1-800-59-ROUSH, 9:00 AM to 5:00 PM EST.

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 2015-2016 F-150 3.5L Ecoboost V6, 2015-2017 F-150
2.7L Ecoboost V6 – Performance Pack Level 2

PACKING LIST FOR 2015+ FORD F-150 OFF-ROAD EXHAUST KIT

Description Part Number Quantity
Flange and Pipe to Connect to Factory 1115-5G267 1
Front Inlet Pipe 1115-5246 1
Muffler 1115-5230 1
Over-Axle Pipe 1115SE-5C262 1
Y-Pipe for Tips 1115SE-5255 1
Tips 1113SE-5230TIP 2
Exhaust Clamp Kit 1115-EXCLMPKIT 1
Tip Clamps 10-0338 2
Pipe Clamps 10-0439 4
Y-Pipe Hanger Bracket 1111-5A204 1

EQUIPMENT AND SUPPLIES REQUIRED

• Metal-Cutting Device (Band Saw, Hack Saw, Cut-off Wheel)
• Ratchet with Extensions
• Metric Socket Sets (deep recommended)
• Torque Wrench

If you are missing any items, please call us toll free at 1-800-59-ROUSH.

1115TT-PWRPK2 07252017 14 800.59.ROUSH

2015-2016 F-150 3.5L Ecoboost V6, 2015-2017 F-150
2.7L Ecoboost V6 – Performance Pack Level 2

LIMIT OF LIABILITY STATEMENT

The information contained in this publication was accurate and in effect at the time the publication was approved
for printing and is subject to change without notice or liability. ROUSH Performance Products (RPP) reserves the
right to revise the information presented herein or to discontinue the production of parts described at any time.

SAFETY PRECAUTIONS
STOP STOP
CAREFULLY READ THE IMPORTANT SAFETY PRECAUTIONS and WARNINGS BEFORE PROCEEDING
WITH THE INSTALLATION!
Appropriate disassembly, assembly methods and procedures are essential to ensure the personal safety of
the individual performing the kit installation. Improper installation due to the failure to correctly follow these
instructions could cause personal injury or death. Read each step of the installation manual carefully before
starting the installation.
• Always wear safety glasses for eye protection.
• Place ignition switch in the OFF position.
• Always apply the parking brake when working on a vehicle.
• Block the front and rear tire surface to prevent unexpected vehicle movement.
• If working with a lift, always consult vehicle manual for correct lifting specifications.
• Operate the engine only in well-ventilated areas to avoid exposure to carbon monoxide.
• Do not smoke or use flammable items near or around the fuel system.
• Use chemicals and cleaners in well-ventilated areas.
• Batteries produce explosive gases, which can cause personal injury. Therefore, do not allow flames, sparks or
flammable substances to come near the battery.
• Keeps hands and any other objects away from the radiator fan blades.
• Keep yourself and your clothing away from moving parts when the engine is running.
• Do not wear loose clothing or jewelry that can get caught in rotating parts or scratch surface finishes.
• Allow the engine, cooling system, brakes and exhaust to cool before working on a vehicle.

WORK SAFELY!
Perform this installation on a good clean level surface for maximum safety and with the engine turned off.

1115TT-PWRPK2 07252017 15 800.59.ROUSH

 2015-2016 F-150 3.5L Ecoboost V6, 2015-2017 F-150
2.7L Ecoboost V6 – Performance Pack Level 2

SECTION A – DISASSEMBLY SECTION B – ASSEMBLY

The following section will guide you through the The following section will guide you through the
disassembly and removal of the stock components. assembly and installation of the ROUSH components.
Longer wheelbase vehicles will also have an 1. Loosen the rear spring support bracket bolt so
intermediate pipe (not shown) between the factory that there is a gap of about 7-10 mm of threads
resonator and the muffler. showing.
1. Remove the two (2) bolts that secure the
intermediate pipe and resonator to the catalyst
pipe. Set these fasteners aside as they will be
re-used.
2. Loosen the clamps that secure the intermediate
pipe and resonator to the muffler and tail pipes.
3. Remove the hanger in the center of the vehicle
at the rear of the muffler. This will aid in removing
and installing the exhaust components.

4. Remove the intermediate pipe and resonator from

the vehicle.
5. Slide each of the hangers out of the rubber
hangers and remove the factory muffler/tail pipe 2. Position the new catalyst pipe adapter flange into
assembly from the vehicle. place against the catalyst pipe and loosely install
the two (2) take-out fasteners to hold it in place.
3. Position the new muffler outlet axle pipe into
position and install the steel hanger brackets into
the factory rubber hangers. Orient the pipe such
that the flared end faces forward in vehicle. At
this time, re-install the hanger bracket that was
removed in step 3 of the Disassembly section.
4. Insert one (1) 3" clamp over the outlet end of the
new muffler assembly and slide this into the end
of the muffler outlet pipe. Position the clamp on
the joint and loosely secure.

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2015-2016 F-150 3.5L Ecoboost V6, 2015-2017 F-150
2.7L Ecoboost V6 – Performance Pack Level 2

5. There is a list of the cut lengths for this 12. With the full system now hanging in the vehicle,
intermediate pipe at the end of this document. Be make sure all of the hangers are fully seated and
sure to leave enough length for engagement into there are no clearance issues with vehicle parts
the catalyst pipe flange. Mark the pipe and double contacting the exhaust system.
check BEFORE cutting to ensure it will be cut 13. With the system in the desired position, torque all
correctly. four (4) 3" clamp joints to 50 Nm.
NOTE: This intermediate pipe has to be cut to length 14. Torque the two (2) catalyst adapter bolts to
prior to final installation to fit your particular vehicle 44 Nm.
wheelbase.
15. Torque the two (2) 2.5" clamps on the tips to
6. Remove the intermediate pipe and cut the pipe 50 Nm.
at the marked length to fit your wheelbase. Make
16. On the eco-boost vehicle, there are two (2)
sure to double check your measurement prior to
hangers at the muffler. The most forward hanger
cutting the material. Cut off the end OPPOSITE
can be removed. Store this with your stock take-
the hanger that is welded to the pipe. Remove all
off exhaust.
sharp edges after cutting.
7. Re-install the pipe assembly to the catalyst flange.
Loosely install the two (2) fasteners.

8. Install one (1) 2.5" clamp onto each of the exhaust

tips and slide the tips onto the ends of the Y-pipe.
Position the clamps on the pipe joints and loosely
secure the clamps.
9. Insert one (1) 3" clamp over the end of the new Congratulations!!! You have completed the
Y-pipe assembly and slide into position on the installation of your new ROUSH Performance
end of the muffler outlet pipe. Products, F-150 Off-Road Exhaust Kit. It is
10. Insert the Y-pipe hanger into the hanger bracket. recommended that you save all parts removed from
It is important to note the orientation of the your vehicle during the installation of this kit.
bracket as it will hang underneath the suspension
bracket.
11. Slide the new rear tailpipe support bracket
between the head of the bolt and the frame. Re-
torque the bolt to 185 Nm. When torquing the leaf
spring bolt, this must be done with the vehicle on
the ground, not on a hoist. The vehicle must be
under its own weight.

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 2015-2016 F-150 3.5L Ecoboost V6, 2015-2017 F-150
2.7L Ecoboost V6 – Performance Pack Level 2

CUT LENGTHS PER WHEELBASE

122.4 wheelbase (19.6 inches)

141.1 wheelbase (38.3 inches)

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2015-2016 F-150 3.5L Ecoboost V6, 2015-2017 F-150
2.7L Ecoboost V6 – Performance Pack Level 2

145 wheelbase (42.2 inches)

156 wheelbase (54 inches)

163.7 wheelbase (no cut for this wheelbase)

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