S&B 75-5038 User Manual

Installation Instructions

P/N: 75-5038 / 75-5038D

Vehicle Applications

Year: 2004-2005 Chevrolet
Make: Chevy/ GMC
Model: Silverado 2500 & 3500

Sierra 2500 & 3500
Engine: 6.6L Duramax Diesel “LLY”

Notes

Kit may not fit with the following
Aftermarket Parts installed:

Body Lift or Lowering Kit

•
Custom Hood

•
Throttle Body Spacer/ Upgrade

•

1. With the ignition switched off, place

vehicle in Park and or set Parking Brake.
Then disconnect both negative battery
cables.

10mm Wrench & Socket

•
T-20 Security Torx Wrench (Supplied w/ Kit)

•
4mm Allen Wrench

•
5/16” Nut Driver or Flat Blade Screwdriver

•
Phillips Screwdriver, Pliers or Channel locks

•
12mm Socket

•

CARB Status - Exempt

Tools required

CARB EO #: D-590-4

Legal for use in CA or other states

adopting CA emissions standards

See Page 3 for more info.

2. Loosen the hose clamps at the OE air

box and at the turbo inlet, then remove the
OE intake tube.

Cleanable (KF-1035). If the enclosed filter is Red, it came pre-oiled
from the factory. Please visit www.sbfilters.com for exact oil
amount required after cleaning.

Disposable (KF-1035D). If the enclosed filter is White, it is a
disposable filter and should be discarded once it reaches capacity.
This filter (does not require oil). For more info on S&Bʼs disposable
filter, visit www.sbfilters.com.

Before You Start

S&B Filter Maintenance

Please read the entire product guide before proceeding.

•
Ensure all components listed on page 4 are present.

•
If you are missing any of the components, call our customer

•
support at [phone].

Do not work on your vehicle while engine is hot.

•
Make sure the engine is turned off and the vehicle is in Park or

•
the Parking Brake is set.

3. Disconnect the MAF sensor electrical

connection.

4. Lift up and pull towards the engine to

remove the OE air box from the vehicle.

7. Attach the S&B Filter Adapter (K) to the

S&B Air box (E), secure using the 5/16
screws (Q) provided.

5. Remove the OE foil from the inner fender,

this will allow cooler air to enter the S&B Air
Box(E).

8. Place the S&B Air Box assembly into the

vehicle, align the 4 holes with the OE
mounting locations and secure using either
the OE bolts or the supplied hardware. You
may need to loosen these bolts to align the
tubes properly during step # 12 then
retighten.

6. Remove the OE air box tray. If long

enough you may use four of these bolts to
secure the S&B Air Box (E) to the vehicle. If

not use the M6 Allen head screws (R) and SS
washers (S).

9. Slide the Step Adapter (M) over the small

end of the S&B Intake Tube (O) and secure
the # 64 Hose Clamp (P).

SEE EXPLODED VIEW ON PAGE 4

15461 Slover Ave., Fontana, CA 92337 - Phone: [phone] - Fax: [phone] - www.sbfilters.com

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Installation Instructions (continued)

P/N: 75-5038 / 75-5038D

#60

10.Slide the large side of the Hump Adapter

(J) over the large end of the S&B Intake Tube
(O) until the small side hits the end of the

tube.

13. Use the T-20 Security Torx Tool supplied

and remove the MAF Sensor from the OE air
box.

11. Place the # 60 Hose Clamp (N) over the

turbo inlet and a # 64 Hose Clamp (L) over
the filter adapter (K). Then slip the S&B Intake
Tube assembly over the turbo inlet, align the
large end of the tube to the filter adapter then
secure the # 60 hose clamp (N).

#64

14. Peel the backing from the MAF Sensor

Gasket (H) before placing it over the sensor,
sticky side down.

12. Slide the S&B Hump Adapter (J) over

the filter adapter (K), center over the gap
between the tubes and secure the #72 and
#64 Hose Clamps (L).

15. Place the M4 screws (I) through the

MAF mounting holes, then place the Rubber
Washers (G) over the screws. Insert the MAF
sensor into the S&B Filter Adapter (K) (note

the direction of air flow) and tighten the M4

screws evenly. Do Not Over Tighten!

16. Reconnect the MAF sensor electrical

connection.

19. Place the clear lid on the air box and

secure using the 8/32 SS Screws (A) and SS
Washers (B).

17. Place the S&B Air Filter (D) into the S&B

Air Box (E), slide onto the flange and secure
the # 80 Hose Clamp (F).

20. Reconnect both negative battery cables.

Inspect your installation, make sure kit is
properly positioned and all fasteners are tight.

18. Remove the protective covering from

the S&B Clear Lid (C).

SEE EXPLODED VIEW ON PAGE 4

15461 Slover Ave., Fontana, CA 92337 - Phone: [phone] - Fax: [phone] - www.sbfilters.com

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