• Cold Air Intake for Ford Super Duty/Excursion (1999-2005) 6.8L V10 Engine
  • Cold Air Intake for Ford Super Duty/Excursion (1999-2005) 6.8L V10 Engine Default Title

Cold Air Intake for Ford Super Duty/Excursion (1999-2005) 6.8L V10 Engine

$169.95
$169.95 $199.99
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Performance Cold Air Intake System for 2000–2005 Ford Excursion 6.8L V10 – Enhanced Combustion Efficiency & Consistent Power Gains

Ensure your Ford Excursion's maximized airflow and engine performance boost with this precision-engineered cold air intake system. Engineered specifically for the massive 6.8L 415 cu in V10 SOHC engine, this kit replaces the restrictive factory air box that often limits the potential of your heavy-duty SUV during long hauls or demanding climbs. By utilizing a heavy-duty powder-coated heat shield to isolate the intake from engine bay temperatures, this system provides the cooler, denser air charge needed for peak combustion efficiency and a more capable driving experience.

The factory intake components are designed for silence over speed, often creating bottlenecks that restrict the V10's ability to breathe under load. Cooler air carries more oxygen, which translates into a more intense explosion in the combustion chamber to create more horsepower and torque. This system utilizes a high-flow aluminum intake tube and an enclosed shield that effectively reduces heat soak, allowing your engine to act as a more efficient air pump and providing a performance increase of 8–10% throughout the entire RPM range.

Key Features & Performance Benefits

  • Power Gain: Increases horsepower and torque by 8–10% for superior towing and highway merging.

  • Thermal Management: Features a heavy-duty powder-coated heat shield to block hot engine bay air.

  • Instant Response: Streamlines the intake path to provide a more direct connection between the pedal and the pavement.

  • Engine Tone: Enhances the unique, powerful induction sound of the 6.8L V10 under heavy acceleration.

  • Consistent Flow: Maintains steady air velocity for reliable performance in large-platform sport utility vehicles.

  • High Filtration: Blocks harmful debris while allowing maximum airflow for high-displacement engine demands.

Vehicle Fitment

Ford Excursion

2000–2005 XLT, Limited, XLS, and Eddie Bauer models

6.8L 415 cu in V10 SOHC GAS (Naturally Aspirated)

(Direct-fit application; no tuning required)

What's Included

Your kit features the high-flow aluminum induction piping, a reusable performance air filter, a heavy-duty powder-coated heat shield, and all required couplers, clamps, and hardware for a complete and secure installation.

Installation Tip

Disconnect the NEGATIVE GROUND CABLE from the battery before starting the installation and keep it off for at least one minute after you finish. This reset allows the engine's computer to learn the new airflow parameters. Ensure the engine is completely cool before beginning work.

Engine Safety Rating
Difficulty 

Fitment

Make

Ford

Engine Size
  • 6.8L

Year
  • 1999
  • 2000
  • 2001
  • 2002
  • 2003
  • 2004
  • 2005

Installation & Tools

The Wrench Time

  • Estimated Time: 45-60 Minutes
  • Difficulty: 3/10 - Basic bolt-on, but requires patience with 20-year-old brittle plastics and delicate sensors.

Tools You Will Need

  • 8mm and 10mm sockets with a 1/4-inch drive ratchet and extension
  • 10mm wrench (for battery terminals)
  • T20 Torx bit (for the factory MAF sensor)
  • Flathead screwdriver or panel popper (for harness clips)
  • Needle-nose pliers (for factory hose clamps)
  • 3mm or 4mm Allen wrench (for aftermarket MAF hardware)
Mechanic’s Pro Tip (The "Gotcha"):
The 6.8L Triton V10 generates massive underhood heat. Because of this, the factory PCV breather hose and the main rubber "zip-tube" on your 1999-2005 Ford Excursion 6.8L will be baked hard and incredibly brittle. Do not muscle them off; gently twist to break the seal. Furthermore, the Mass Air Flow (MAF) sensor is highly sensitive. Never touch the internal wire element, or you will cause a permanent hunting idle condition.

Phase 1: Removing the Factory Part

  1. Disconnect the Battery: Always start by disconnecting the negative battery terminal using a 10mm wrench to prevent check engine lights and reset the ECU’s fuel trims.
  2. Unplug the MAF Sensor: Locate the MAF sensor on the factory airbox. Slide the red locking tab back, press the release clip, and gently pull the harness off. Use a panel popper to unclip the harness wire from the factory airbox housing.
  3. Remove the MAF Sensor: Using your T20 Torx bit, carefully remove the two screws holding the MAF sensor. Pull the sensor straight out and place it on a clean rag in a safe location.
  4. Disconnect the PCV Breather: Locate the PCV hose connecting to the side of the factory intake tube. Use needle-nose pliers to squeeze the clamp, slide it back, and gently twist the hose off the plastic fitting.
  5. Loosen Clamps and Remove Tube: Grab your 8mm socket and loosen the hose clamps at the throttle body and the airbox. Pull the factory rubber intake tube off.
  6. Extract the Airbox: Remove the factory airbox mounting bolts using a 10mm socket and extension. Lift the entire lower airbox assembly out of the engine bay.

Phase 2: Installing the Cold Air Intake for Ford Super Duty/Excursion (1999-2005) 6.8L V10 Engine

  1. Assemble and Mount the Heat Shield: Assemble the new aftermarket heat shield and weatherstripping. Drop it into the factory mounting locations and bolt it down securely using your 10mm socket.
  2. Transfer the MAF Sensor: Carefully insert the factory MAF sensor into the new aluminum or plastic intake tube. Ensure the sensor is facing the correct direction (airflow pointing toward the throttle body). Secure it using the provided aftermarket hardware and an Allen wrench. Do not overtighten, or you will crack the mounting flange.
  3. Position the Silicone Couplers: Slide the provided silicone couplers onto the throttle body and the heat shield opening. Slip the heavy-duty T-bolt clamps over the couplers but leave them loose.
  4. Route the Intake Tube: Thread the new intake tube into the couplers. Reconnect the factory PCV breather hose to the new machined fitting on the tube, securing it with the factory clamp using needle-nose pliers.
  5. Lock It Down: Once everything is aligned without binding, tighten all T-bolt clamps using a 10mm deep socket. Reconnect the MAF sensor harness and push the red locking tab back in securely. Install the new high-flow air filter onto the end of the tube and tighten the clamp with an 8mm socket.
  6. Relearn the ECU: Reconnect the negative battery terminal using your 10mm wrench. Start your 1999-2005 Ford Excursion 6.8L. Do not touch the gas pedal for at least 20 seconds. Let the vehicle idle so the ECU can adapt to the massive increase in airflow from your new intake.

Disclaimer: This is a general guide provided for the 1999-2005 Ford Excursion 6.8L. Always refer to your factory service manual for exact torque specifications and safety procedures.

Warranty

All products are backed by our Limited Lifetime Warranty. We stand by our quality. [See terms]
Cold Air Intake for Ford Super Duty/Excursion (1999-2005) 6.8L V10 Engine

$169.95