For 2004 through 2008 4.2L V6 and 4.6L V8 models, start by disconnecting the PCV fresh air inlet hose from the air intake duct, then loosen the hose clamp at the Air Filter Box end and disconnect the duct. Next, loosen the hose clamp at the throttle body end, disconnect the duct from the throttle body, and remove it. Installation follows the reverse order. For the Air Filter Box, disconnect the electrical connector from the MAF sensor and detach the retainer, then disengage the housing locator pins and the fresh air inlet duct from their grommets. Inspect the rubber grommets for any damage and replace if necessary, followed by reinstallation in reverse order. For 2004 through 2008 5.4L V8 models, remove the air intake duct retaining bolt, then pull the fresh air inlet end out of the fender and the outlet end out of the Air Filter Box before removing the duct. Reinstallation is the reverse of removal. For the Air Filter Box, first remove the air intake duct, disconnect the electrical connector from the MAF sensor, and disconnect the PCV fresh air inlet tube quick-connect coupling. Remove the four mounting bolts and the Air Filter Box-to-throttle body seal, inspecting it for damage and replacing if necessary, then reinstall in reverse order. For 2009 and later models, drain the cooling system until the expansion tank is empty, disconnect the PCV fresh air inlet tube quick-connect coupling, loosen the clamps securing the outlet pipe, and remove it. Disconnect the electrical connector from the MAF sensor, remove the air filter element, disconnect the expansion tank overflow hose, and remove the expansion tank/Air Filter Box lower housing mounting bolts before lifting the tank out of the engine compartment. Reinstallation follows the reverse order, and refill the cooling system with the appropriate antifreeze.
Posted by FordPartsGiant Specialist 
