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Roush Performance Power Pac; Level 1 (18-20 5.0L F-150)

Item T542521
AmericanTrucks no longer carries the Roush Performance Power Pac; Level 1 (18-20 5.0L F-150). Please check out 1997-2003 Ford F-150 Power Packages for an updated selection.
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    Video Review & Installation

    The Level-1 power pack here from Roush is an extremely basic and also extremely easy way to squeeze up to 18 horsepower and 26-pound feet of torque to the tires out of your 5-liter equipped 2018 and newer F-150. Now, the kit will include the Roush Cold Air, as you can see, along with the corresponding calibration voucher offer right around that $900 price point.Installation for the intake itself will be a breeze, however, that calibration will need to be flashed by your local dealer, unless that is you do have access to the J2534 interface tool. So, therefore, just expect a solid one out of three wrenches on the difficulty meter and about an hour or so to complete from start to finish.So, the Roush power packs have been an extremely popular extremely reliable way to squeeze more power and torque out of your mustang or truck for years now. And the same is gonna be said here for the newer F-150 and the 5-liter power plant. Now, those advertised numbers again of 18 and 26 do come directly from Roush but us having our in-house dino jet here, we want to put that to the test. So we strapped down our 2018 5-liter truck, ran it on 93 octane, and here are those results. Baseline run, using our 2018 5-liter F-150 with 93 octane in the tank, gave us 334 horsepower and 339 pound-feet of torque at the rear wheels. With the Level-1 Roush power pack installed and 93 octane, the truck is now making 349 horsepower and 355 pound-feet of torque, again, at the rear wheels. That makes for a peak gain of 15 horsepower and 16 pound-feet of torque over our baseline numbers and gains of as much as 21 horsepower and 24 pound-feet of torque under the curve.But with the power numbers out of the way, let's talk a little bit more about the Roush power pack here. And at first glance, the Level-1 kit is a very basic system. Right? Half of the kit will be the very solid Roush cold-air-intake system which is going to ultimately replace that factory air box and cheap paper element factory filter. Now, in that place, you're gonna look at a reusable high-flow dry filter from Roush and quality sealed air box.Now, the Roush filter will not only be an improvement in filtration and appearance, I guess you could say here, right, but also things like less intake restriction, which is gonna help result in a little bit more power, and things like improved throttle response.Finally, guys, not as important of course but certainly worth noting, a more modified look under the hood, thanks to the cool sealed enclosure here and window that helps you keep an eye on your filter's condition. Now, because this thing is sealed, recently Roush did move to a sealed enclosure. You can also look forward to things like slightly lower intake air temperatures when compared to other aftermarket systems that might incorporate an open-element-style filter.Now, the second part of the Level-1 kit is gonna be the Roush calibration. And while, yes, it is included with the power pack, what you're really receiving here, guys, is this voucher that you will need to take to your dealer to get flash to your truck using the tool we talked about earlier. So don't expect to receive a handheld tuning device or anything like that because that's simply not the case here at the Roush kits. But once that calibration has been flashed to your truck, you can expect to see similar gains to what we showed you earlier, using the intake, along with the calibration, on at least 91 octane or 93 octane fuels.Now, this is very important to point out because, yes, you still can use this system with lesser octane fuels, 87, 89, ideally, you're not gonna see the big gains, like we talked about in this video, unless you're using the premium or higher octane fuels. Why? Well, the truck is gonna be happier, it's gonna see more ignition timing, and therefore, you're gonna make more power overall. So, at the end of the day, it's a 12-1 motor guys, high-compression, do yourself a favor and run premium fuel.Now, that increased power is made possible thanks to things like improved camshaft timing, focus on throttle mapping to give the truck a sportier feel overall, and again, improved throttle response. Now, if you did wanna take advantage, Roush does offer an additional 3-year 36,000-mile warranty but you have to apply for that with Roush directly and it must be done so immediately after the installation.But what do you say we switch gears and briefly talk about the installation? And again, not too difficult here guys. Basic cold-air install's gonna get a strong one out of three wrenches on the difficulty meter, using some pretty basic hand tools. But again, you will need to factor in the caveat of either scheduling a trip to your dealer, which is about an hour's worth of labor here, to flash a truck or, if you have a buddy that has access to a pass-through device, like the J2534, for instance, you can do it on your own time, as long as you download the Roush RDT software. But without further ado, here's that walk that we promised you earlier, along with a quick tool breakdown.Tools I used for this installation include a 3/8 ratchet. A 1/4-inch ratchet. A 1/4-inch extension. A 7-millimeter socket, 8-millimeter socket, 10-millimeter socket, 13-millimeter socket, T30 Torx tool, pin removal tool, flat-head screwdriver, and a cordless ratchet or impact.All right guys, kicking off our Roush power pack install, the first step here is obviously remove our factory intake. Really not that difficult. We're gonna start by loosening up the clamp here at the throttle body.With our connection at the throttle body all loose, now we're gonna move over to this 13-millimeter bolt that secures the air box to the inner fender area. We are gonna remove this now with our 13-millimeter socket but don't lose this bolt because it will be used in future steps.All right, moving right along, now we just need to disconnect any of our hoses connected to our factory intake tube, on our truck. There are two right here, and then, also this breather for our coolant reservoir that we're gonna have to move just to remove the factory intake. Remove these clips. Press down on the black. Pull back. With the PCV hose, there's actually a little tab here, you're gonna wanna push down on this. You can see me pushing it right now with my finger. Push down and pull back.I'm just gonna disconnect this clamp here, at the air box, this will allow us to separate the air box from the tube itself. Again, there's a couple of different ways to remove your factory air box but we're gonna just do it this way. All right, that clamp loosened up. Separate our intake tube. Watch our coolant overflow line here. Angle out of place.Now, before we yank our air box out of here, we do also have to yank out the snorkel at the same time, since they are connected. In order to do so, simply grab your panel removal tool, flat-head screwdriver, whatever you have, and remove these two clips next. All right, with those two clips removed, we can yank the entire air box assembly and duct door snorkel out of the engine bay.Now we can get started assembling our Roush intake system. I found that easier to do it on a workbench or a table, rather than working in the engine bay myself. First things first, we're gonna get our hose connections in place along with these two little rubber grommets. Now, with these grommets, I found that spraying with a little soapy water, or something just to kind of give it some sort of lubrication to get in the hole, makes the job a little bit easier.Now, for our second one, again, spray a little bit of soapy water on it. And sometimes I also found that, if it's being a little stubborn, grabbing a flat-head screwdriver to kind of finish off the job is another good way to do it. So, like to get it started...All right, applying our [inaudible 00:08:43] soapy-water technique, grab a little soap-water mixture here for the grommet along with the smaller fitting which goes closest to the filter opening. And same thing for the larger PCV fitting, a little soap and water here, a little bit on the opening.Now we can grab our couplers, and then, apply them or install them onto the intake tube, starting with our small one. At this point, you can put a couple of clamps over the coupler loosely, just get them in place for later on.The clamp, at the plastic intake tube, you can actually snug up a little bit the clamp that's gonna be used to secure to the throttle body. Leave that loose, obviously, because we still need to install that. I just like to get it in place so it's ready to go once we're ready for the installation. Now I can move on to the larger coupler at the filter side.Again, install our clamps. The larger clamps here are gonna use an 8-millimeter socket, whereas the smaller ones are gonna utilize a 7-millimeter socket. So we can tighten up this clamp here at the larger connection. And we'll tighten this one up loosely but obviously, again, not too tight because we need to connect this portion here yet to our filter. I just like to tighten it up enough so it won't slide off the coupler.With our intake tube fully prepped, we can set this aside for now. We're gonna work on our air-box portion next. And for that, you need to grab your filter of course, along with your filter adapter and the air box itself. Now, you will notice the air box here, the filter adapter is going to live in here where it's gonna be secured by the two 10-millimeter bolts that are included with the kit. And that's gonna live in there. So, with that being said, you wanna situate the filter and, more importantly, the clamp in a way that you can actually access the clamp here at any given point. So, when it's time to clean your filter, you can gain access to this with your socket or your flat-head easily, just so it's not on the bottom side of the filter or something like that, making it very difficult to remove. So, with all that said, let's start throwing this thing together.First up, we're gonna grab our Roush filter. Grab our filter adapter. Slide that into place. Again, referencing these two holes here, I'm gonna make sure we can access this clamp pretty easily. So, right about there looks nice. And now grab your 8-millimeter socket and tighten it up.With our clamp nice and tight, we can grab our Roush air box and insert the filter assembly and adapter through the hole in order to secure these 2 10-millimeter bolts now. Start each bolt by hand, a couple threads. Once you have them started, you can grab your 10-millimeter socket and tighten them down.All right, we're almost ready to throw our new Roush intake in the engine bay. But before we do, we do need to separate the snorkel or inlet from the factory air box because it will be reused here with our Roush system. In order to do so, grab your 8-millimeter socket. There is one little screw right here connecting the two, go ahead and remove that next.With that screw removed, a lot of times you need to help the snorkel out from the factory air box, give it a little help. I like using a panel removal tool or sometimes a flat-head screwdriver. Whatever you have access to in order to pry from the inside of your air box out.With our snorkel now separated, we can insert that and install it into our Roush air box in reversed order. Stick it on in. And again, we are gonna secure it using that same screw we removed in the first step with our 8-millimeter socket.Now, before we toss the Roush in the engine bay of our 5-liter truck, we thought it'd be a good idea to pull them both on the table, kind of show you the differences between the two. And, side by side, it's pretty obvious. Right? The biggest difference is going to be your filter. Whereas the factory air box utilizes that cheap paper element factory filter, it's kind of a one-and-done thing, it gets dirty, you toss it every year or so. The Roush, on the other hand, is gonna feature a reusable dry filter that's gonna equate to roughly 20% to 30% less restriction than the OE filter. What does that mean? Well, that's where you're getting the power, that's where you're getting a little bit more miles per gallon, and a little bit more sound.Now, one thing you can say about the factory air box is, well, it's a sealed enclosure, you're not gonna get as much heat soak as you would with an open-air enclosure like the Roush. However, with 2018, Roush gave you a lid for their air box. So, now you have a sealed enclosure as well, if you'd like, or you can leave the top off and get more of that sound that kind of is more reminiscent of an aftermarket intake, more of that growl, and so on. So you got the best of both worlds, here at the Roush, and I really dig that.As for the tubes themselves, well, side by side, you can see the diameter of the Roush is certainly a little bit larger, as is the capacity of your air box. Just a really well-made unit, I really like the Roush systems because, again, it gives off a factory style of build, if you will. It's not flashy, there's not a ton of logos stamped all over it. And I think it's great because of that kind of the less is more approach, while delivering the goods.So, now that you know the slight differences between the two, what do you say we get this installed?Before we actually drop the new Roush air box in place, we do need to reinstall that 13-millimeter bolt I told you about earlier, along with the rubber grommet that you took off your factory air box.With that grommet in place, now we can grab our Roush air box and lower it into place. But I do wanna show you, guys, just a couple feet down here, basically these little pegs that need to sit into these two little rubber grommets. Once you have those situated, make sure the side of the air box is situated in the rubber grommet and you should be good to go.With our air inlet in place or our snorkel, now we're gonna grab our Christmas-tree clips and go ahead and reinsert those. All right, we've got a Roush tube kind of fish it in the engine bay here. I'm gonna get the throttle body connected first to the coupler. Put that in place. Go ahead and get the big coupler situated on the filter adapter. All right, we've got a coupler in place here. Grab our 7-millimeter socket, tighten things up.Now we're switching to our 8-millimeter socket, we're gonna tighten up this clamp here at the filter adapter.All right, we're almost home free. But now we have to reattach our PCV and hose lines, push them into place.All right, at this point, the installation of the Roush intake itself is pretty much complete. However, if you do wanna install the lid that is included with the kit, you need a T30 Torx tool to get the included screws in place. Get them all started by hand here.Now, at this point, you can grab your T30 Torx tool, whether it be on a ratchet, cordless ratchet, whatever you have, and secure all of your bolts.And with our final bolts tightened up, that wraps up the installation of the Roush intake for our power pack Stage-1 here with our 2018 and newer 5-liter truck. Now, at this point, most of you guys at home are probably just gonna have to drive to the dealer with your voucher in hand and get your tune flashed by your local dealer. Or, if you happen to have a J2534 passenger device, at this point, you would complete the calibration.Now, I do wanna point out, this is not a tune required intake, so therefore, you can install this, drive to the dealer with no issue whatsoever. Hey, we hope you enjoyed this review and install of the Roush power pack Stage-1 kit, again, available for your 2018 and your 5-liter truck. And keep in mind, for more cool products and videos like this, keep it right here at

    Product Information

    Features, Description, Reviews, Q&A, Specs & Installation


    • Roush Power Pack - Level 1
    • Increases of over 18 RWHP and 26 ft/lb RWTQ
    • Improves Throttle Response
    • Roush Cold Air Intake Kit Included
    • Reusable High Flow Dry Air Filter
    • Calibration Optimized for 91 Octane Fuel
    • Flashed via a J2534 Interface Tool - A Dealer Service Charge May Apply
    • Optional 3 Year/36,000 Mile Limited Powertrain Warranty Available
    • NOT CARB Certified
    • Fits 2018-2020 5.0L Equipped F-150 Models


    Unleash Performance. Maximize the performance of your Coyote powered F-150 with a Level 1 Performance Power Pac that was developed and tested by calibration engineers over at Roush Performance. This performance power pack features a Cold Air Intake and PCM Calibration that allows your F-150 to run stronger and better than before. A straight power hike of +18 RWHP (rear-wheel horsepower) and +26 RWTQ (rear-wheel torque, in ft-lbs) result from the flood of cold air the Power Pac admits into your truck’s 5.0L engine. The Power Pac also creates a sporty induction noise and grants better throttle response.

    Engine Must be Flashed with Roush Tune. An aftermarket tune/flash is required in order to use the Roush Level 1 Power Pac – in fact, the RDT (Roush Diagnostic Tool) utility and the flash included in the kit are considered part of the whole. The RDT software is included, as well as a flash card voucher. The actual flashing is carried out using industry standard J2534 interface tools which may require the services of dealer (dealer fee not included).

    Easy-to-Use Oil-Free Filter. The air filter of the Roush Level 1 Power Pac is made out of non-oiled synthetic material and is designed to be washable and reusable. The absence of oil makes it easier to prep the filter for use – there is no chance of adding too much or too little oil. The filter element is strengthened and given a better, more even shape by two layers of fine wire mesh inside the synthetic fabric body.

    Manufactured for Endurance. The cold air intake in the Roush Level 1 Power Pac is made from plastic, with an injection-molded enclosed air box and a roto-molded high-density polyethylene tube that will stand up to years of use and abuse. Both parts are black, with a textured surface for extra visual interest. The couplers are EPDM rubber, allowing the intake to move as the engine rocks and twists in action. The magenta filter element is synthetic fabric, and the clamps are stainless steel.

    Easy Physical Installation. Even a novice can install the Roush Level 1 Power Pac’s physical component, using ordinary hand tools to carry out a bolt-on application. The intake comes with all the hardware and clamps needed to mount it. Please note that flash tune of the ECU is also required to make the intake work properly once installed.

    90-Day Warranty with Optional Extension. Besides carrying a 90 day limited manufacturer’s warranty, the Roush Level 1 Power Pac has an optional 3 Year/36,000 Mile Limited Powertrain Warranty which is available through Roush. The optional warranty must be purchased within 30 days of the service installation date. Click here to see more details.

    Not California or CARB Legal. This product is not legal for use in California or any other state adopting California emission standards. Not legal for use on pollution controlled motor vehicles; intended for off road use only.

    This Roush Level 1 Performance Power Pac is specifically designed for use on 2018-2020 F-150s equipped with the 5.0L Coyote V8 engine.

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    Installation & What's in the Box

    Installation Info

    What's in the Box

    • (1) Upper Airbox Cover Assembly
    • (1) Airbox Tray
    • (1) MAF Tube - No Insert
    • (1) Clear Air Tube
    • (1) Air Filter
    • (6) M6 x 25mm Self Tapping Screws
    • (2) MAF Tube to Airbox Bolts
    • (1) Airbox to Tube EPDM Coupler
    • (1) CAT to T-Body EPDM Coupler
    • (1) 3/8 in. PCV Fitting
    • (1) 5/8 in. PCV Fresh Air Fitting
    • (2) 5/8 in. Grommets
    • (2) MAF Tube to Air Tube Worm Drive Clamps
    • (2) 90-110mm x 12mm Stainless Clamps
    • (1) Power Pac Calibration Card
    • (2) Roush Stickers

    Customer Reviews (24)

      Questions & Answers

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