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  • 2009-2012 Ford F-150 S&B Intake And Dynomax Ultra Flo Cat-Back Exhaust Install

2009-2012 Ford F-150 S&B Intake And Dynomax Ultra Flo Cat-Back Exhaust Install

Deep Breaths: Bolt-On Performance

Maxwell Matthewson
Aug 27, 2014
Photographers: Maxwell Matthewson
We constantly preach that lifting your truck on bigger wheels and tires kills performance and mpg. There are ways to reclaim everything you lost and more, but if you recently spent thousands on a lift and wheels and tires, the last thing you want to do is drop thousands more on performance upgrades. The quickest and easiest way to reclaim some of that lost power is to upgrade the intake and exhaust systems. The OEMs try to find the right balance of decibel levels and mpg. Unfortunately, that means there is some power and torque left on the table. It is our job to find it.
For this F-150, we called S&B and ordered its intake kit (PN: 75-5050, $299.00). The kit includes a smooth-bore intake tube for even airflow through the intake and a larger airbox. There are also options for an oiled, cleanable filter or a dry cotton disposable filter and an intake scoop for added airflow. For our project, we chose the disposable filter and no scoop. The exhaust we ordered was the Dynomax Ultra Flo cat-back system (PN: 39486, $285.99), featuring a welded muffler with straight-through design. The muffler uses Dynomax’s exclusive Continuous Roving Fiberglass to absorb unwanted interior drone. When the parts arrived, we pulled them into our tech center and got to work bringing back some lost power and torque.
1. The intake and exhaust helped us regain some of that lost power from the heavier wheels and tires. The added rumble was a nice touch as well.
Photo 2/19   |   2009 2012 Ford F 150 Intake And Exhaust Install 02
2. With the truck safely on a four-post lift, we got to work removing the offending pieces. The easiest way to remove the exhaust was to cut the tailpipe off the muffler.
Photo 3/19   |   2009 2012 Ford F 150 Intake And Exhaust Install 03
3. Once that was cut and the hangars were lubed up, the tailpipe was removed from the truck.
Photo 4/19   |   2009 2012 Ford F 150 Intake And Exhaust Install 04
4. Next, the muffler was loosened and removed from the head pipe and tossed in the scrap heap. The head pipe was then unbolted from the Y-pipe.
Photo 5/19   |   2009 2012 Ford F 150 Intake And Exhaust Install 05
5. The new Dynomax kit is a single-exit rear with a polished tip. It comes with all the necessary hardware and detailed instructions to make installation a breeze.
Photo 6/19   |   2009 2012 Ford F 150 Intake And Exhaust Install 06
6. The first piece to go on was the head pipe, which was clamped to the Y-pipe. All the clamps were hand-tightened until everything was installed.
Photo 7/19   |   2009 2012 Ford F 150 Intake And Exhaust Install 07
7. Next, the muffler was fit onto the end of the head pipe.
Photo 8/19   |   2009 2012 Ford F 150 Intake And Exhaust Install 08
8. Using the included band clamps, the components were, again, hand-tightened.
Photo 9/19   |   2009 2012 Ford F 150 Intake And Exhaust Install 09
9. A new hangar is included in the kit, keeping everything aligned with the factory specs.
Photo 10/19   |   2009 2012 Ford F 150 Intake And Exhaust Install 10
10. Finally, the polished tip was installed and all the clamps were tightened to the recommended torque values.
Photo 11/19   |   2009 2012 Ford F 150 Intake And Exhaust Install 11
11. Under the hood, the factory intake was about as ugly as they come. The convoluted rubber hose and resonating chambers didn’t help the airflow, either.
Photo 12/19   |   2009 2012 Ford F 150 Intake And Exhaust Install 12
12. Loosening two hose clamps allowed us to remove the intake tube from the throttle body and airbox.
Photo 13/19   |   2009 2012 Ford F 150 Intake And Exhaust Install 13
13. Next the mass airflow sensor (MAF) was unplugged from the factory airbox.
Photo 14/19   |   2009 2012 Ford F 150 Intake And Exhaust Install 14
14. Two bolts held the factory airbox in. The airbox and coolant reservoir are one piece and lifted right from the vehicle. Luckily, the S&B kit comes with a replacement reservoir, so we tossed this whole unit in the trash.
Photo 15/19   |   2009 2012 Ford F 150 Intake And Exhaust Install 15
15. As stated, the kit includes the new airbox, smooth intake tube, a coolant reservoir, and all the necessary hardware.
Photo 16/19   |   2009 2012 Ford F 150 Intake And Exhaust Install 16
16. To begin, we slipped the new coupler onto the throttle body and slid the intake tube into that.
Photo 17/19   |   2009 2012 Ford F 150 Intake And Exhaust Install 17
17. The airbox was next and used the factory hardware and mounting locations.
Photo 18/19   |   2009 2012 Ford F 150 Intake And Exhaust Install 18
18. Plumbing the reservoir involved connecting a hose from the radiator to the bottom of the reservoir.
Photo 19/19   |   2009 2012 Ford F 150 Intake And Exhaust Install 19
19. To finish off the install, the filter was installed and the acrylic lid was screwed in place.

2015 Ford F-150 Specifications

VIEW ALL
Fair Market Price $24,627
MSRP $26,030
Editors' Overall Rating
Mileage 18 City / 25 Highway
Engine 3.5L V6
Horse Power 283 hp @ 6,500 rpm
Torque 255 ft lb of torque @ 4,000 rpm
See all Specifications

Sources

S&B Filters
Ontario, CA 91761
800-358-2639
www.sbfilters.com
Dynomax Performance Exhaust
Monroe, MI
734-384-7806
Dynomax.com

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Ford F 150

Fair Market Price
$24,627
Editors' Overall Rating
Basic Specifications
MSRP: $26,030
Mileage: 18 / 25
Engine: 3.5L V6
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