IMPORTANT NOTE!!! My scoop is the Series 1 NOT a bolt in fit for the HD... Sorry to Tim for not clarifying that up front... Also.. for anyone who reads this... this install is simple.. if you can change a tire in Khaki slacks with minimal dirt on your pants you can do this... sorry for any confusion!!
What you will need:
** std & deep metric 1/4" & 3/8" sockets, extentions, u-joint, rachets
** (2) 3/8 or (2) 9-10mm speed clip/u-nuts & matching 1.25" overall length bolts (the stockers are just not quite long enough)
** cordless drill, 3/16" drill bit, & a 3/4" Uni-bit
** (2) good sized flat screwdrivers or pry bars.
** beverages
Initial notes..
1.) the as delivered system uses the stock HE hardware to install the scoop. The stock 10mm lower HE bolts are just barely long enough. the instructions say the OEM bolts go through the scoop legs, through the lower HE bracket hole & into the speed nut on the bumper. yeah... I don't think so. Additionally, the wrestling match of manipulating the scoop, bolts etc & NOT scratching paint is nearly impossible... being on the ground on your back... impossible... there is just not enough room unthere for both hands, a ratchet or wrench, the bolt & balancing everything...
So my solution was to remove the lower grill (j-jent or stock) move the OEM Speed-Nuts from the bumper, & install the speednuts on the legs of the scoop, & run the bolts from the bumper side (through the lower grill opening). LOTS more clearance in FRONT of the bumper... I make it sound SOO easy.. getting the stock speed-nuts off SUCKS... I had to cut mine & pry them out.. just FYI...
compare this to what you see on your stock bumper:
Sorry I didn't get the before pic or a pic of the speed nut on the scoop leg(s). maybe later when I swap HE's I'll update.
2.) as delivered the scoop will hang just below the lowest point of the front valance & about 1 1/16" below the stock HE. If you have no plans for an upgraded HE or not immediately & want the scoop up close... do this:
Measure down on the legs exactly 2" down. mark this. then mark from the left/right 1/2" (the legs are 1" wide overall) on your previous 2" mark for your drill point. Drill with the 3/16" bit to start. then take your 3/4" unit bit & run it all the way through. This gives you a hole just large enough for the Speed-nut to sit flush/correctly & a little wiggle room for alignment. I will update pics of the drilled legs soon. the final installed "adjusted" scoop will look like this:
tight to the Stock HE
if you update the HE, you can go back to the as delivered for the larger HE.
3.) Install the flex brake ducts on one end of the metal tube. Use a twisting motion to "roll" the duct over the tube. Add the (2) loose clamps for future use. Install & tighen the clamps to secure both flex hoses. Pay attention to where the clamps face, once they are in the truck, you want to be able to get to them with a ratchet.
4.) take an 8mm socket & remove the (2) bolts holding the HE pump/bracket as an assembly. just carefully let it hang on its hoses.
5.) lower the flex hose/metal tube/spare clamps from the top... LONG HOSE GOES TOWARD THE SCOOP (DOWN). Leave it loose... trust me... loose. The long flex hose goes BETWEEN the fan shroud & the rubber/metal trans cooler line.. the cooler line keeps it up & positions it in line with the scoop.
6.) Lay another clamp over the end of the scoop nipple. slip the long hose over the end of the scoop. once over & down about 1/2"-3/4" install & tighten the clamp. Reinstall the HE/Pump bracket assembly... the flex tube will look like this:
7.) back up top. Lay the metal tube/clamps/flex hoses over to the passenger side. Install the (2) aluminum brackets provided. the one that is tweaked goes on top. Here is the installed metal tube with the brackets clearly visible.
That is where I am today... I have to run get the connection for my Volant air box & then install the final clamp on the end of the short flex hose.
Rob W
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Originally Posted by 2002GreyHD150
no worries... I gotto thinking.. the front of my truck has been apart 4 times for paint in '05... who knows the body shop may have messed with some of the mounting points...