'99.5-'02 Ford Power Stroke 7.3L

 Cold Air Intake Systems

(PN 54-10061, 54-10191 & 54-10192)

The 1999-2002 Ford Power Strokes has a nice large engine 7.3L displacement. But it still struggles for pick-up and go like many diesels.  Once the turbo kicked in and you were cruising at highway speeds, power and torque was nice but off the line, the story was something else. 

In looking at the stock intake, you wonder what the Ford engineers were thinking when they designed such a small filter for such a large engine.  However, we have to thank Ford for the opportunity this created for us.  We recognized that we could get a more responsive vehicle if we could let this turbo charged diesel breathe better.

The Stage 1 intake system for the '02 Ford Power Stroke (PN 54-10191) was one of the first diesel intake systems our engineers designed.  It has continued to be one of the best selling kits. 

The simple but elegant air box, made of tough 16 gauge steel powder-coated with a dirt resistant wrinkle-black finish, snaps into place where the stock air box cover sits.  The top of the air box is trimmed with a rubber trim that seals to the hood to keep hot engine power robbing air from entering the intake tract.  A nice touch that shows our engineers attention to detail is the rain guard that keep water and snow from accumulating in the air box.  A bracket and tube was included to accommodate the factory  filter minder that was new to the 2002 model.

The only difference between the 2002 Stage 1 above and the 1999.5 and 2001 Stage 1  (PN 54-10061) is the provision for the factory filter minder.  In the earlier '99.5-01 model.  Although our engineers could easily have capped off the tube on the first-developed 54-10191, our commitment to the details of the application lead us to introduce a different part number all together. 

Both these intake systems utilize a high flow, conical cone filter that increases airflow 150%.  This increase in airflow has a dramatic impact on the power that the 7.3L turbo diesel engine generates. 

Notice is the dyno curve and at what RPM the max gain in horsepower and torque occur.  You can see that, by letting the engine breathe better, the power becomes available much earlier where you need when towing or climbing.

Even though we got the 7.3 Power Stroke to breathe better and produce more power with our Stage 1 systems (PN 54-10061 & 54-10191), we knew there was more power to be had given the huge displacement of the engine.  The restriction in putting a larger cone filter in the stage 1 intake systems was the battery box that was right in front of the air box.  We couldn't just move the battery some place else because the battery holder was integrated to the bottom half of the air box to which our Stage 1 attached. 

After a lot of thought and numerous designs, our engineers came up with the design you see here, our Stage 2 cold air intake system (PN 54-10192).  We replaced the entire stock air box and battery holder with our own air box.  By replacing the stock battery tray/air box, we were able to have room for a huge oval air filter with a 6" inlet.  The filter is massive when compared with even our own Stage 1 filter let alone the stock paper filter. 

The system includes a uniquely designed intake tube that tapers from the 6" air filter inlet to that stock 4" turbo inlet.  This tapering helps to accelerate the air and further enhances performance. 

With out the battery, the air box looks like a humongous air scoop. That's what it ended up being because the performance gains were phenomenal.   The combination of the air box design and the huge air filter it allowed, the performance improvement was beyond our wildest dreams.  You could feel the difference of  having all that torque available so earlier in the RPM range.  Rather than waiting for the power to come on, you had the power right away. 

All three systems use our multi-layer oil-impregnated cotton gauze filter that are designed to flow better, hold more dirt and is washable.  That means you can use it over and over again.   Although our intake systems cost more initially, the benefits in longer service cycles, better fuel economy, not to mention the great "seat-of-the-pants" acceleration you feel far out weigh the cost. 

With our diesel intake systems, we offer two different filter media depending on your driving needs.  Our standard media is constructed of 5 ply cotton gauze sandwiched between aluminum mesh.  This media is great for normal every day city and highway driving where really dusty dirty environments is not a big problem.  But if you live in the desert or agricultural communities or if you drive in dirty conditions like in construction or mining, then you need a little more protection.  We offer this added protection with our patented Pro-GUARD 7 media which is 7-ply cotton gauze and non-woven synthetic fabric sandwiched between aluminum mesh.  Both media will flow better than the stock paper but Pro-GUARD 7 will offer you a little more protection while the standard Magnum Flow will offer you a little more performance.