Airaid 400-166 Installation Instructions

Installation Instructions

For Part Numbers:

400-166 700-469 Airaid Oiled Media Filter
401-166 701-469 SynthaMax Dry Media Filter - Red
402-166 702-469 SynthaMax Dry Media Filter - Black
403-166 703-469 SynthaMax Dry Media Filter - Blue

2005 Ford Expedition 5.4L V8

Component Identification

1. Airaid Premium Filter 1

2. MAF Panel Black 1

3. Bottom Panel Black 1

4. Black Filter Adapter 1

5. Airaid Intake Tube 1

6. Driver Side Bracket 1

7. Passenger Side Bracket 1

8. Weather Strip 25” 1

9. Urethane Hump Hose 1

10. ¼-20x1/2” Bolt 6

11. 6-32 Screw 4

12. 6-32 Keps Nut 4

13. #6 Flat Washer 4

14. Bushing 4

15. Aluminum Fitting 1

16. 8-32 x 3/8” Button Screw 2

17. M6-1 x 25 Hex Bolt 3

18. M6 Nut 2

19. ¼” Flat Washer 9

20. Rubber Grommet 2

21. Bracket 1

22. Grommet 1

23. Bracket 1

24. ¼”NPT x 3/8” Barb 1

25. Plastic Hose Mount 2

26. #72 Hose Clamp 2

Full color instructions can be viewed on our web site at Airaid.com. Use the Product Search function to find your part number, and click View Details.

1.Disconnect The Negative Battery Terminal!
Grasp intake tube and sharply lift up and away from
airbox.

B

2. Grasp large oval section of intake tube and pull up

and away from inner fender well, and remove entire
intake tube. (Note: Intake tube is held in with rubber
grommets, no bolts.)

B

3. Remove 13mm nut on power steering reservoir brack-

et. Install Airaid intake tube support bracket, replace
nut, and leave slightly loose. (Nut will be tightened

after final adjustments.)

A

C

A

D

4. A.) Remove breather line by pushing up on green lev-

er and pulling fitting away from airbox. B .) Remove
vacuum line from clip. C.) Pull up on, and remove heat­er control valve from tower bolt. D.) Pull up on, and
remove wiring harness from tower bolt.

C

5. A.) Unhook the mass air flow sensor by pulling out

the red plastic tab first, and then remove the plug.
B.) Unhook the vacuum line. C.) Remove all four
tower bolts and remove air box. (Save tower bolts

for reinstallation.)

C

A

B

B

A

6. A.) Remove the two factory grommets by sliding side-

ways. B.) Install the two supplied grommets in reverse
order.

B

A

7. Remove the factory rubber seal from the airbox, and

install it on the Airaid intake tube.

8. Remove the mass air sensor from the stock airbox
using the #20 torx tool. A .) Using the supplied
8/32 screws install the mass air sensor in the
Airaid intake tube. B.) Install the 3/8” plastic hose
fitting. Do not over tighten! C.) Install the sup-
plied grommet, and then the supplied aluminum
fitting, rounded end first.

9. A.) Assemble the Cool Air Da m using the four 6-32
screws and locknuts. B.) Install the air filter adapter
using three ¼-20 Allen bolts and washers.

10. Mount the Airaid Cool Air Dam assembly to the
vehicle using the supplied metric bolts and washers. The
bolt on the right goes into the factory threaded hole. The
two bolts on the left go thru the CAD, the grommets,
and then the supplied bracket, with the nuts on the bot­tom. (Note: T he mounting bracket must be on the bot-
tom of the grommets.)

A

11. Install the urethane hump hose and two #72 hose

clamps. (Leave loose until final adjustments are
made.)

12. Install the two Airaid intake tube brackets on the
top of the intake manifold, using the four alumi­num spacers on top of the bracket and the four
tower bolts. (Leave loose until final adjustments

are made.)

13. Install the Airaid intake tube over the throttle body,
and into the hump hose. A .) Install the two ¼-20
Allen bolts and washers thru the brackets and into
the tube. Push down on the throttle body end, and
lift up on the curve of the tube. Make sure the tube
is seated all the way down on the throttle body!
Tighten the Allen bolts, and then the tower bolts.

16. Install the Airaid Premium Filter inside the cold air
dam.

14. Install a ¼-20 Allen bolt and flat washer thru the
bracket at the back of the tube, and tighten. Tighten
the nut at the bottom of the bracket. Tighten the
hose clamps on the hump hose.

17. Install the weather strip on top of the cool air dam.
(Hint: Start at one end and work towards the other
for an easier fit.) Spread the two hose mounts over

the radiator overflow hose, and insert one in each
hole at the ends of the cool air dam.

15. Reconnect the Mass Airflow Sensor and vacuum
hose. Reconnect the breather line, and vacuum
line in the clip. Reinstall the wire harness, and
heater control valve on the tower bolts.

18. Check for foreign materials in the
intake, recheck your work. Check
nuts, bolts, and clamps for tight­ness. Reconnect the negative bat-

tery cable.

Thank you for purchasing the Airaid Intake System. Contact Airaid @ [phone] 8:00 AM - 5:00 PM MST weekdays for questions
regarding fit or instructions that are not clear to you. Your Airaid Intake System was carefully inspected and packaged. Check that no parts are
missing, or were damaged during shipping. If any parts are missing, contact Airaid. The air filter element is protected from direct exposure to wa­ter and debris; care should be taken not to drive through deep water. WATER INGESTION IS THE DRIVERS RESPONSIBILITY! The air filter
is reusable and should be cleaned periodically.

FILTER IDENTIFICATION

700-469 Airaid Oiled Media 701-469 Airaid SynthaMax Dry Media - Red

702-469 Airaid SynthaMax Dry Media - Black 703-469 Airaid SynthaMax Dry Media - Blue

For your Oiled media filter

we suggest using the AIRAID

Filter Tune-Up Kit!

Synthamax Air Filters do not require oil.
Service air filter as needed by cleaning with
common non-petroleum all-purpose house­hold cleaner and water. Simple Green®,
Formula 409® or equivalent works great.
Apply cleaner to outside of air filter and
allow to soak. Then flush filter clean from
the inside out with a garden hose and re­peat steps if necessary. Do not apply high
pressure water or air to clean filter. Allow

P/N 790-551 Aerosol Spray

filter to air dry and reinstall.

P/N 790-550 Squeeze Spray

Airaid Filter Co. 2688 E Rose Garden Ln. Phoenix AZ 85050 [phone] [e-mail] www.airaid.com

REV.10.23.13