INSTALL MANUAL: Gen V Mustang

 

The following Installation Instructions apply to the 2005-2010 Ford Mustang 4.0L SOHC models (also very similar to the 2005-2010 Ford Explorers with the exception of initial disassembly). Prior to proceeding, confirm that your engine bay looks similar to the following photo:

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You should read the entire instruction manual prior to proceeding with your installation.

It is important to familiarize yourself with the ModdBox Supercharger Kit installation.  It is the responsibility of the installer to properly install the Supercharger Kit.  To ensure safety and proper installation, ModdBox recommends that this product only be installed by a qualified professional with access to pneumatic tools and a strong familiarity with automotive service procedures.

Tuning is not covered in this manual.

Moddbox is an automotive parts supplier only and tuning services are not offered.  However, Moddbox provides customer support for your parts installation and can provide guidance regarding tuning options.  In addition, Lasota Racing provides online tuner services to many of our customers.  For more information about Lasota Racing’s online tuning services, visit our Lasota Racing – Online Tuning Manual here.

REFERENCE ABBREVIATIONS

EGR – Exhaust Gas Recirculation

HVAC – Heating Ventilation & Air Conditioning

IAC – Idle Air Control

MAF – Mass Air Flow

TPS – Throttle Position Sensor

Vac – Vacuum

TOOLS REQUIRED

Standard metric socket set

Hex key set

Various pliers

T-30 Torx bit

Fluid funnel

Oil pan

Flat head screw driver

Pneumatic or electric hammer drill

Crescent wrench

Utility knife

Shop vacuum

Rat tail file

Propane torch or similar heating device

Wire Strippers

Wire Crimper

STOCK REFERENCE DIAGRAMS

Stock Intake Pipe & Air Box Reference Diagram

AirBox&Tube

Stock Exhaust Gas Re-circulation (EGR) Reference Diagram

EGRsystemRef

Throttle & Stock Intake Manifold Reference Diagram

throttlebody

Ignition Coil Reference Diagram

ignitionCoil

Belt Diagram Reference Diagram (Dark Belt Showing the ModdBox Orientation)

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MODDBOX SUPERCHARGER KIT PARTS

Only key components in the kit are shown here.  Refer to the parts list provided with your product for a complete list of product components.

ModdBox Supercharger Bypass Valve

Supercharger Bypass Valve

 

ModdBox 5.5.0 & 8.0 psi Supercharger Pulleys

Ranger Sport Trac Explorer B4000 3.0 psi pulley

ModdBox Quick Change Pulley Adapter

AdapterPully

ModdBox Plenum Bottom Plate

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ModdBox Plenum Top Plate

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ModdBox Intake Manifold

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ModdBox Intake Manifold Top

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ModdBox Stainless EGR Extension

EGRextention

Black Silicone Liquid Gasket

Black Silicone Liquid Gasket

Moddbox 6PK Serpentine Belt

6pkBelt

INSTALLATION STEPS

SUPERCHARGER INSTALLATION (5-6 hours)

Disconnect TPS plug and Electronic Throttle Plug.

Throttle Body Removal Mustang

Disconnect MAF plug.

maf mustang v6

Disconnect Crank Case Vent hose from the Intake Hose.

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Disconnect EGR plug and EGR vac line.  Remove the EGR valve and set aside for future use.

2005 2006 2007 2008 2009 2010 Mustang EGR Valve

Disconnect Spark Plug Wires and remove the Plug Wire Retaining Clip from the top of the Stock Intake Manifold.  Disconnect the Vac Line and Fuel Vapor Return Line as shown.  Mark them with tape if necessary.

moddbox supercharger plug wire removal for supercharger kit installation

Disconnect Electrical Plug Mount from Stock Intake Manifold.  Use the supplied short plastic straps to secure this to your wiring harness or fuel rail as required.

moddbox plug mount

Disconnect the passenger side Crank Case Ventilation Tube.

moddbox crank case vent tube removal for supercharger

Remove the two bolts shown.  This will disconnect your Stock Intake Manifold from your Ignition Coil Mounting Bracket.

moddbox ignition coil disconnect

Disconnect the plug to your Ignition Coil.

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Pry your Ignition Coil assembly toward the Driver Side (the assembly should be displaced by approximately 2-2.5″ to allow for the future relocation of your EGR valve).

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Remove the Stock Rubber Intake Tube and set it aside for future use.

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Disconnect the Throttle body.  You may want to loosen the Coolant Line Retaining Clips to allow the coolant lines to twist on their mount points.  Place the Throttle Body aside for future use.

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Use a T-30 Torx bit and remove the eight bolts that connect the Stock Intake Manifold to the Engine Block.  The bolt locations are shown below:

4.0 v6 mustang blog bolt locations

Clean and vacuum the area if necessary.  Be sure to clean the Engine Block’s mating faces.  Caution:  Do not drop anything into the Intake Ports.  Before Proceeding, fill the Intake Ports with rags or paper towel.

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Place a bead of RTV Black Liquid Gasket around the engine’s inlet ports as shown.

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Obtain the Moddbox Lower Plenum and fit the Future Intercooler Inlet/Outlet ports with the provided NPT plugs.  Place a bead of RTV Black Liquid Gasket around the ports openings as shown.

Optional:  If you have purchased a ModdBox IAT/ACT relocation kit, install the provided IAT/ACT sensor and wire harness to the red highlighted location as shown below.  Connect two wires to the harness using and route them to the front of the vehicle towards the MAF.  Refer to the IAT/ACT relocation instructions for further information.

Optional:  If you have purchased a ModdBox Intercooler Kit, replace the provided NPT plugs highlighted green below with the provided NPT hose fittings.  Refer to the ModdBox Intercooler Kit Installation Manual for further instructions.

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Caution: The Plenum Base Plate is NOT reversible.  Before placing the Plenum Base Plate on the Engine Block, note the orientation of the lower plenum.  The front of the lower plenum has a bulge as shown in the picture below.  Torque the provided M6x35 SHCSs to 13lbft.  Start at the center bolts and work your way to the ends in a cross-pattern.

orientation

Remove the stock alternator shield.

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Remove the Coolant Cap.  Locate the plastic Radiator Drain Valve at the bottom passenger side of the Radiator.  Turn this plug and release approximately a gallon of coolant fluid (~4L).

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Remove the Stock Upper Radiator hose and set it aside for future use.  Remove the Thermostat Coolant Elbow and replace it with the one provided as shown.  Be sure to clean the mating flanges and replace the o-ring.  Failure to do so may result in a coolant leak.

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Replace the Stock Upper Radiator hose with the one supplied.  The Throttle Body Coolant Hoses will need to be re-arranged as shown.

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Obtain the Moddbox Intake Manifold and install the brass fittings as shown (2x 1/4″ NPT Plugs and 2x 1/4″-3/8″ Barbs).   Use the hardware and RTV Black Liquid Gasket to securely bolt the supplied block plates as shown.  Install the Supercharger Bypass Valve as shown.  The NPT Plug shown below is for an optional Future Methanol Injection Port.

Optional:  If you plan to install a methanol injection kit, it is advisable to install the methanol injection nozzle at this time.

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Connect the 14″ long 3/8″ hose to the 3/8″ Barb as illustrated below.  Secure it with one of the provided stainless hose clamps.  Leave the other end loose until a later step.

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Obtain your Eaton M90 Supercharger  (either an 89-93 oval or 94-95 rectangular style M90) and the provided ModdBox Stainless Steel Supercharger Pulley Adapter.  Remove the supercharger’s flange bolt and ensure the shaft key is inserted and aligned.

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Use a propane torch to pre-heat the Stainless Steel Pulley Adapter (allowing it to thermally expand).  Slip the supercharger Adapter onto your supercharger shaft until it binds.  Note:  The pulley is designed to have an interference fit which will cause the pulley to jam once it slips halfway onto the shaft.  If you do not have a torch, simply placing the adapter in a cup of boiling water should expand the adapter enough to proceed.

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If you did not use a torch, the threads of the supercharger shaft might not be exposed.  Use a hammer and a socket and gently tap the Adapter further down the shaft until the first few threads on the supercharger shaft are exposed beyond the Stainless Adapter bore as shown below.

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Utilize the stock Eaton M90 Supercharger Lock Nut and two box wrenches.  Use one wrench to prevent the Adapter from rotating  (utilizing the flats on the stainless steel part) and use the other wrench to apply torque on the Supercharger Lock Nut.  Continue to torque down the nut until the back of the Adapter hits the stop on the Supercharger shaft.  Caution: Be sure that no debris falls into your Eaton M90 Supercharger.  The tolerances on your supercharger is only ~0.003″-0.007″ and can be damaged if material gets sucked into the supercharger housing.  Rotating the rotors by hand can generate enough air flow to suck debris into the rotors.  Use a vacuum to clear your rotors prior to installation.

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Obtain the provided ModdBox 6PK Custom Pulley and slip it onto the Supercharger Pulley Adapter.   Caution:  The pulley is a machined precision slip-fit (only when both parts are room temperature).  You must either heat the Pulley or wait for the Adapter to cool prior to slipping it on.  No force should be required.  The pulley will not bind if it is slipped on straight.

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Rotate the pulley and align the  M5 threads with the pulley holes (should rotate freely if slipped on correctly).  Torque down the provided M5x16mm socket head cap screws.

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Obtain the Moddbox Plenum Top Plate.  Install the 1/8″ NPT and 1/4″ NPT Brass Plugs as shown.  These plugs have been provided for the use of optional intake temperature and boost senors/controllers.  Apply a bead of the RTV Black Liquid Gasket to the Moddbox Plenum Top Plate flange as illustrated.

Optional:  If you plan to install a boost gauge or intake temperature sensor, it is advisable to install them at this time.

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Obtain the ModdBox Plenum Top Plate and bolt it to the base of the Eaton M90 Supercharger & Pulley Assembly. Use the provided M8x40mm socket head cap screws.  Clean any excess gasket material.

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Obtain the Stock Upper Radiator Hose that was previously set aside.  Measure out and cut a length of hose as is required for your supercharger:

For the 94’-95’ Eaton M90 Supercharger (rectangular inlet):  1-7/8”

For the 89’-93’ Eaton M90 Supercharger (oval inlet):  2-5/8”

Use one of the 2” stainless hose clamps to secure the hose to the Plenum Top Plate.  Loosely place the other 2” diameter stainless hose clamp on the hose.

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Use the RTV Black Liquid Gasket and put a thin bead on both the Supercharger and the Moddbox Intake Manifold.  Press the Moddbox Intake Manifold Assembly onto the hose prepared in a previous step.

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Bolt the Moddbox Intake Manifold to the back of the Supercharger using the provided four M8x25 SHCS bolts.  Use the RTV Black Liquid Gasket to seal the Moddbox Custom Washer in place as shown (the bolt located inside the Intake Manifold).  Tighten the 2″ stainless hose clamp around the bypass valve.

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Note:  The Moddbox Custom Washer must be reversed for the 94-95 Superchargers (orientation shown is for the 89-93 superchargers).

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Use the RTV Black Liquid Gasket and place a bead around the Intake Manifold Top Flange.  Place and bolt-up the Intake Manifold Cover as shown.  This whole Supercharger Assembly will be used in the next steps.

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Remove the rags or paper towels in your Engine Inlet Ports.  Apply a thin bead of Black Liquid Gasket along the Plenum Base Plate.  Caution:  Be sure to apply gasket material around all the bolt holes (as illustrated in the photo below). The gasket material must be extended to the inside edge of the mating face as shown on the bottom-left of the photo below. Failure to do so can result in a leak in your Intake Manifold Assembly.

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(Note:  Engine rags/paper towels removed from engine ports prior to installing Plenum Top Plate)

Place the whole Supercharger Assembly on the Moddbox Plenum Bottom Plate.  Align the holes and bolt it down using the twelve M8x30 hex bolts.  Do not forget the bolt under the Supercharger Snout.  Torque the bolts in a cross-pattern.

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Locate the disconnected Fuel Vapor Return Line.  Cut off the press fit connection and reconnect it to the remaining 3/8” barb on the ModdBox Intake Manifold.

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Connect the fuel Vapor Return Line to the un-used Barb as illustrated.

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Use the provided 1/4″ Tee and connect the Brake Boost and Vac Lines to the 14″ long 3/8″ diameter hose connected to the Supercharger Assembly (prepared in an earlier step).  Secure the Vac lines with the provided hose clamps.

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Connect the Moddbox Flexible EGR Extension to your EGR valve.

Caution:  The Stainless Steel EGR Extension is not designed to be twisted.  Do not twist the EGR Extension when tightening the threads or damage to the extension may occur. 

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Install the EGR Valve using the Moddbox EGR Spacer and the provided M8x40 SHCS bolts.  Note:  The provided spacer is anodized black (raw aluminium shown).

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Install the Throttle Body.

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Bend the Stainless Steel EGR Extension to suit.  Secure it with the provided C-clamps as shown.  Connect the EGR Extension to the stock EGR re-circulation line.

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Use a knife and carefully cut your Stock Rubber Intake Pipe along the center of the ribs as shown.  Be sure to count the ribs and confirm the exact location for cutting.

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Use your knife and carefully carve out the ribs to allow for a stainless hose clamp.

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Install the Moddbox Intake Pipes using the Stock Rubber Intake pieces and the provided hose clamps.

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Install the 5/8″ diameter hose to the Crankcase vents as shown connecting the PCV valve (from driver-side crank case cover) to the Moddbox Intake Manifold’s brass 90degree elbow fitting (at bottom behind supercharger).  Connect the passenger-side vent to the intake pipe immediately downstream of the air filter.  Use the provided elbow and stainless steel hose clamps to securely fasten them together.

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Use the provided wire and butt crimps to extend your Electronic Throttle, TPS, and EGR plugs.  Use the loom and remaining plastic strap to secure and clean-up the wiring once completed.  Plug the wires back into the TPS and EGR.

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Slack your Belt Tensioner using a 3/8” Box Wrench or Belt Removal Tool.  Remove the Stock belt and replace it with the ModdBox 6PK Belt as illustrated below.

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Plug in the MAF sensor, reconnect the disconnected Ignition wires, top up the coolant level, and reconnect the battery.  The last step required is to wait 24 hours.  You must allow the liquid gasket material to fully cure at room temperature or as per the manufacturer’s recommendations.  Failure to provide the necessary curing time may lead to vacuum leaks.

CONNECTION CHECK LIST

MAF sensor plug

EGR Vac Line to EGR Valve

EGR Stainless Recirculation Line (if equipped)

Crank Case Vent Hose to Intake Tube (may be 2 depending on your model)

IAC Electrical Plug (may need to check polarity on the wiring extension)

TPS Electrical Plug (may need to check polarity on the wiring extension)

Electronic Throttle Plug

Ignition Coil Plug

Fuel Vapor Return Line

Fuel Injection Vacuum Line

Brake Booster Vacuum Line

 

INITIAL DRIVING & TUNING INSTRUCTIONS

Running the 3.15″ diameter pulley (max 5.5psi)

At minimum, you will require the installation of larger injectors (suggest 39+lb/hr), colder plugs (suggest 1 heat range colder with 0.035″ gap – ex NGK TR6GP), higher octane fuel, and an ecu remap.  We also recommend upgrading your fuel pump to a high flow 255lph (optional), installing cooling equipment such as a methanol injection kit or intercooler (optional), and scaling your MAF to avoid pegging (optional).  Moddbox assists customers with tuning by suggesting an online tune shop, Lasota Racing.  We also sell an SCT firewire to PLX module cable and a compatible A/F Module & Gauge Combo Package that makes tuning easy.  For more information, please contact us at info@modd.me.

Running the 2.9″ or 2.64″ diameter pulley

When using the 2.9″ or 2.64″ diameter pulleys, you will exceed the 5V limit of your stock MAF sensor.  You will be required to scale your MAF (using a product like the DiabloMAFia or similar) or upgrade it to high flow MAF.  Talk to your tuner for more information.

Starting Your Vehicle for the First Time 

Caution:  Be sure you have waited 24hrs for your liquid gasket material to fully cure prior to proceeding.  

If you are unsure about whether you have correctly installed everything described in this manual, please spend some time to review the instructions and consult the “connection check list”.

Once the checklist has been consulted…  it’s time to turn the key :)   Your vehicle should start up exactly as it did before.  It may however turn over once before starting if the fuel lines where not fully primed.  If your vehicle idles rough, you have probably missed a vacuum line.  Consult the installation steps above.

RECOMMENDATIONS

Tuning is the most important component of ensuring you get the most out of your Moddbox Supercharger Installation Kit.  Shopping around for a qualified tuner that has experience with Mustangs is highly recommended.

Making sure your vehicle does not run lean is very important.  Installing an optional Air to Fuel (AFR or A/R) gauge with a wideband oxygen sensor is recommended.  As a rule of thumb, an AFR while in boost and running premium street fuel of 11.5 is optimum.  Having a gauge is great way to monitor the operation of your supercharged engine.

As discussed, we recommend either installing either Methanol Injection or an Intercooler Kit for all boosts above 3.0 psi. Forced induction adds heat to the intake air as a result of compression.  This added heat can increase your exhaust gas temperatures (EGTs) during extremely harsh driving conditions.  These EGTs could adversely affect your vehicle.  This risk can be mitigated by installing cooling equipment (intercooler or methanol injection).  You can also mitigate this risk by installing an EGT gauge and keeping the temperatures below 1500 degF.  As a rule of thumb, never go over 1600 degF.

TROUBLESHOOTING COMMON PROBLEMS

Idle is Erratic

If your idle rises and falls in a repeating pattern, you have a massive Vacuum leak.  One of the items on the connection list was likely missed.

Vehicle makes a whistle sound when driving

You probably have a kink in your crank case ventilation hose or a vacuum leak.

Squealing Pulley

The removal and replacement of a new belt may have caused your worn idler pulley to start squealing.  Apply lubrication or replace your idler pulley.

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Thank you for choosing Moddbox!  We would love to hear how we can make this installation manual better.  If you feel we could improve it in any way, please let us know by emailing us at info@modd.me.

Submit your build photos!  We love seeing your builds.  Please submit your Name, State/Province, and some photos of your vehicle and we will add you to our customer build section.

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