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JOHNNY LIGHTNING RAM AIR STAGE 2
INSTALLATION STEPS
This particular installation was done on a
2001 Ford Lightning, but should be 100%
applicable to all models 1999-2001.
Jack up the front of your Lightning and place it on jack stands. Remove
the driver’s side front wheel.
Carefully remove the inner fender liner.
Looking straight ahead you will see three bolts that hold the steering box
in place on the other side. Remove the top bolt and use it to secure the hose
clamp as shown below. Do not tighten it all the way because you will bee some
maneuvering room. The protruding part will end up at a 90-degree angle, the
bottom will point towards the front of the vehicle. It will be a quarter turn
further to the right than the picture below.
Slide the metal tube through the hose clamp, while making sure the end
with the two holes faces downwards. Make sure the clamp fits loosely around
the tube, but do not tighten it yet.
Fasten the black air scoop under the bumper on the driver’s side. Looking
from behind, the right upper side of the scoop will fasten to the lower left
corner of the radiator. Both holes on the left side of the scoop attach to the
metal bracket. This bracket attaches in the upper front bumper assembly to a
round hole (next to a small square hole).
Remove the stock air box and rubber connector to the fender, and make sure
to keep the round rubber seal on the mass-air. Gently pull out the mass air
sensor (the white plug) and note its orientation towards the air stream.
Bolt on the round metal adaptor to the mass-air (use the rubber sealing ring)
and gently plug the mass air sensor into the hole on the adaptor facing the
rear of the engine bay. Make sure it’s pointed towards the air stream just
like before.
Attach the bracket on the bottom of the adaptor to the available hole
below where the original air box sat.
Very gently, push the orange flexible hose through the hole in the fender
where the rubber connector previously attached. The new air filter will seat
snugly between these two pieces. Picture below shows the air filter without
the black filter sock provided. This should be wrapped around the air filter
before it’s placed between the two receptacles and clamped down on both ends
as shown below.
Note: Those with only the air kit, disregard the part about the orange
flexible hose. Simply slide the tube in to the end of the adaptor in the hole in
the fender trim plastic for a neat fit.
Attach the orange tubing to the rubber cup-shaped end-cap, and
use a clamp to attach the other end of the hose to the metal tube. Arrange the
tube as shown below. Make sure to fasten the little screw where the tube
enters the scoop. Gently wedge the tube into the left upper part of the wheel
well.
Adjust the clamps to ensure a good alignment of the pipe. Don’t forget to
tighten the screw into the steering box. Optionally you can use a 20” nylon
cable tie to secure the tube to the frame where it’s wedged in.
Replace the plastic liner and determine how much needs to be cut out to
accommodate the hose. Once you can line up the bolt-holes, you have cut out
enough material. Start with a small slice and work outwards from there.
Note that in this picture I cut out more than needed, Johnny Lightning is now
including a template which will greatly help prevent this. Slide the liner
behind the tube before pulling it tight. This will ensure the proper clearance
between the tire and the tube. You should have around 1” clearance between
tire and tube when the wheel is turned all the way to the right. Please check
for this clearance before test-driving!
Tighten and secure the scoop and check all bolts.
Note: For more air you can re-drill and lower the scoop.
If you have any questions, call or e-mail
jlightningracing@cs.com.
Neither Johnny Lightning (John Wiker), nor Frans Keylard
(the author of this document) are responsible directly or indirectly for
injuries or damages resulting from this product. Buyer is to use at own
discretion.
FOR OFF ROAD USE ONLY!
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Please do not reproduce without permission. ::
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