Bully Dog Rapid Flow Induction User Manual

INSTALLATION MANUAL

Rapid Flow Induction

Vehicle Application Part Number

‘03,’04,’06,’07 Ford 6.0L Power Stroke #51100

‘05 Ford 6.0L Power Stroke #51101

RAPID FLOW INDUCTION

TROUBLESHOOTING:

If you have questions during the installation of this product,
please visit www.bullydog.com/Product_Updates.php.
The latest version of these instructions can be found at the
same location. Please review the Troubleshooting section on
page before calling technical support to cover most common
issues. Technical support is available by calling 866-bully­dog (866-285-5936).

TABLE OF CONTENTS

INTRODUC TION ...............................................................................................PG. 2

BILL OF MATERIALS .........................................................................................PG. 2

REMOVING THE STOCK INTAKE .................................................................... PGS. 34

INSTALLING THE RFI ................................................................................... PGS. 57

FILTER MAINTENANCE .....................................................................................PG. 8

WARRANTY & DISCLAIMER ............................................................................PG. 10

1

RAPID FLOW INDUCTION

INTrOduCTION

Introduction: The following instruction set covers installation and maintenance of the Rapid
Flow induction system for 2003-2007 6.0L Ford Power Strokes. Notice that the installation process
for the 2005 model year 6.0L has installation dierences from the rest of the model years.

PREFILTER RECOMMENDED

Recommended with this kit but not included is a Bully
Dog prelter which can be purchased through a local Bully
Dog dealer. A prelter blocks large particles and insects
from becoming lodged in the lter ribs, this keeps air ow
at a maximum and makes cleaning much easier.

BILL OF MATERIALS

RFI Housing

Filter

Band clamp

Star Torx Bit (not in exclude ‘05)

TOOLS NEEDED

Pliers

Flat head screw driver

Bit Driver - (exclude ‘05)

2

RAPID FLOW INDUCTION

rEmOvINg ThE STOCk INTAkE

1. Disconnect the coolant overll hose, this will make the
removal of the stock intake easier.

2. Disconnect the Mass Air Flow sensor:

• (‘03, ‘04, ‘06, ‘07) Using a bit driver

and the torques bit included unscrew
the torques screws that hold the mass
air ow sensor onto the air intake exit
tube. Once the screws are out pull the
mass air ow sensor out of the tube,
disconnect it from the harness holder
and move it aside while completing
the installation.

• 2005 The mass air ow sensor sits in a

grommet that holds it in place on the
intake exit tube. Remove the MAF sen­sor by simply pulling up on the sensor,
then disconnect it from the harness
holder and move it aside while com­pleting the installation. Also remove
the grommet that holds the MAF sen­sor in place from the stock intake, that
grommet will need to be installed on
the RFI along with the MAF sensor.

3