BOSS 302 Intake Manifold installed on 2024 F-150 5.0

[EL5_Zero]

This past weekend my brother and I confirmed that IT IS possible to run the BOSS 302 intake manifold on the Gen4 5.0 without the use of adapter plates to the heads. We did use an adapter plate for the throttle body that I had laying around from a previous project. It's one used to adapt a GT350 87mm TB to a GT 84mm intake manifold. The plate bolts up to the manifold perfectly, but the lower passenger side bolt on the throttle body is about 2-3mm off.

I decided to try the manifold for the sole purpose of satisfying my curiosity. I bought the manifold over 10 years ago and I never got around installing due to going with the GT350 manifold on my 2015 Mustang GT Performance Pack.

The biggest hurdle was removing material from the manifold to fit around the direct injection system. We removed material with the die grinder until the manifold fit perfectly. I also modified the intake tube to fit by removing the air silencers and patching the holes with epoxy and thin plastic. After that we simply hooked the vacuum lines and fuel lines and the truck fired up right away.

First impressions, I love the look of the engine bay, it looks so much cleaner!

As for power, it definitely feels like it picked up power. The truck pulls hard all the way to redline. I seriously do not feel the loss of torque at the lower RPM's like it's been said on dyno videos.

I will be taking notes over the next few weeks before I give my final thoughts on this mod. So far it was worth the +-5 hrs of labor and a 12pk we spent making it work.

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[jkosh22]

This past weekend my brother and I confirmed that IT IS possible to run the BOSS 302 intake manifold on the Gen4 5.0 without the use of adapter plates to the heads. We did use an adapter plate for the throttle body that I had laying around from a previous project. It's one used to adapt a GT350 87mm TB to a GT 84mm intake manifold. The plate bolts up to the manifold perfectly, but the lower passenger side bolt on the throttle body is about 2-3mm off.

I decided to try the manifold for the sole purpose of satisfying my curiosity. I bought the manifold over 10 years ago and I never got around installing due to going with the GT350 manifold on my 2015 Mustang GT Performance Pack.

The biggest hurdle was removing material from the manifold to fit around the direct injection system. We removed material with the die grinder until the manifold fit perfectly. I also modified the intake tube to fit by removing the air silencers and patching the holes with epoxy and thin plastic. After that we simply hooked the vacuum lines and fuel lines and the truck fired up right away.

First impressions, I love the look of the engine bay, it looks so much cleaner!

As for power, it definitely feels like it picked up power. The truck pulls hard all the way to redline. I seriously do not feel the loss of torque at the lower RPM's like it's been said on dyno videos.

I will be taking notes over the next few weeks before I give my final thoughts on this mod. So far it was worth the +-5 hrs of labor and a 12pk we spent making it work.

That looks stellar
Almost like it should be there from the factory.

 

[Aonarch]

Truck manifold is designed for lower end torque.

I'd think you'd want a tune to adjust for the new manifold.

 

[03PSDX]

That’s really kool man! Engine looks great!

 

[EL5_Zero]

Truck manifold is designed for lower end torque.

I'd think you'd want a tune to adjust for the new manifold.

My truck is a single cab sporty truck, I'm not towing my foxbody or rock crawler with this truck. Trust me when I say, part throttle daily driving with the Boss intake is exactly the same as the truck manifold. The truck accelerates exactly the same at part throttle from light to light. Maybe a combination of being the smallest F-150, 3.73 gears, 2WD, and the 10R80 help it get off the line.

On my truck, it did not lose any noticeable torque. I proved it on my drive home these past three days. Cruise control set at 70 mph and approx. 1600 RPM going up a 6% grade for 4 miles, my truck does not downshift, it stays in 10th gear. With the truck manifold, it would always downshift to 9th.

Also, I've noticed my MPG's are going up. So far I'm averaging 20.5 MPG with the Boss intake, stock tune. For the last 28K miles, I've been getting 18.6 round trip on my commute to my shop driving through a mountain pass.

I need to collect more data before I post my final conclusion. So far, this intake is winning my vote.

As for the Tune, it is not needed to run. That was one of my questions when I decided to run the intake, and these past 250 miles proved it. The Gen4 5.0 does not have IMRC, it's a simple intake manifold with a MAP sensor. Now, if you want the Boss intake to really shine at 7-8K RPM's, then yes, a tune is necessary. That will come in a few weeks. Right now, I will modify to see how parts respond with the stock tune. Long tube headers will also be added prior to the tune.

 

[Davidwnuc]

Any possible issues with deleting the pcv line to the intake tube?

 

[EL5_Zero]

Any possible issues with deleting the pcv line to the intake tube?

I believe you can delete the pcv line from the intake tube and just add a catch can that vents to atmosphere. It would be wise to vent the passenger side pcv as well to maintain a balanced system. Only downside to that method is the smell of oil and a possible dirty valve covers.

I removed the quick release couplers from the pcv hardline and used a 5/8" hose. It was necessary to do this because of the pcv connection on the intake tube being higher in the engine bay and the OEM hose not flexing enough to reach.

 

[EL5_Zero]

I also ported the intake runners quite a bit and shaved down the fuel injector bump that is in the runners. Maybe the port work helped keep lower end torque similar to the stock manifold.

 

[Aonarch]

I also ported the intake runners quite a bit and shaved down the fuel injector bump that is in the runners. Maybe the port work helped keep lower end torque similar to the stock manifold.

Very nice!

 

[25fordlariat]

I believe you can delete the pcv line from the intake tube and just add a catch can that vents to atmosphere. It would be wise to vent the passenger side pcv as well to maintain a balanced system. Only downside to that method is the smell of oil and a possible dirty valve covers.

I removed the quick release couplers from the pcv hardline and used a 5/8" hose. It was necessary to do this because of the pcv connection on the intake tube being higher in the engine bay and the OEM hose not flexing enough to reach.

This confused me. I know I have a PVC on passenger side but is there one on drivers side too? I have a 25 F150 coyote I have a K&N oil catch can that I'm going to install next to battery. You have a really nice set up. Should be proud of your work

 

[EL5_Zero]

As you can see in the picture below, the heads on the Gen4 have some "bumps" that prevent the Boss intake from sitting flush to the heads. These areas are the ones you need to pay attention to and clearance the intake until it fits.

These are the "pockets" on the Boss intake that were trimmed to fit.

Progress picture of the trimming that was done.

Also, it was necessary to remove the metal inserts on the manifold to help align the manifold bolts as seen in the picture above. It allowed just enough room to thread the bolts.

NOTE: One bolt on each side of the manifold I believe between cylinders 2&3, and 6&7 were not used. The bolt location is completely off. Rest assured that those 2 missing bolts DO NOT cause any issues. We tested for vacuum leaks with a smoke test and the manifold sealed up perfectly, including the throttle body.

The EVAP system was not touched at all. It stays in the same location, and you simply connect the hose to the fitting on the driver's side behind the throttle body.

Fuel rail mounts (4) were slightly modified. They were cut down slightly over 1/2", .550 to be exact. Once cut, the fuel rails were rested on the shortened mounts, then the piece we removed were placed on top of the fuel rail flange. This was used for the sole purpose of reusing the stock long thru bolts instead of purchasing shorter bolts.

The mounts had to be shortened because the manifold flange on the Boss intake is .550 thinner than the stock manifold flange. The fuel injects are now sitting .550 closer to head port closer to the valves. Not sure if that has any effect and air to fuel mixture, but the truck runs and drives great at all RPM's.

 

[EL5_Zero]

This confused me. I know I have a PVC on passenger side but is there one on drivers side too? I have a 25 F150 coyote I have a K&N oil catch can that I'm going to install next to battery. You have a really nice set up. Should be proud of your work

Thank you! I couldn't have done it without my brothers help. I have a bad back due to hanging iron for the past 20 years. To answer your question, yes, the driver's side also has a pcv system. However, the driver side doesn't really pull as much oil as the passenger side, therefore the passenger side is the one that usually gets the catch can.

 

[Brent@ANParts]

Looks good on there, following for more. Would love to see some dyno numbers if you end up testing it.

 

[honda250xtitan]

awesome thread.

 

[nvabill]

This past weekend my brother and I confirmed that IT IS possible to run the BOSS 302 intake manifold on the Gen4 5.0 without the use of adapter plates to the heads. We did use an adapter plate for the throttle body that I had laying around from a previous project. It's one used to adapt a GT350 87mm TB to a GT 84mm intake manifold. The plate bolts up to the manifold perfectly, but the lower passenger side bolt on the throttle body is about 2-3mm off.

I decided to try the manifold for the sole purpose of satisfying my curiosity. I bought the manifold over 10 years ago and I never got around installing due to going with the GT350 manifold on my 2015 Mustang GT Performance Pack.

The biggest hurdle was removing material from the manifold to fit around the direct injection system. We removed material with the die grinder until the manifold fit perfectly. I also modified the intake tube to fit by removing the air silencers and patching the holes with epoxy and thin plastic. After that we simply hooked the vacuum lines and fuel lines and the truck fired up right away.

First impressions, I love the look of the engine bay, it looks so much cleaner!

As for power, it definitely feels like it picked up power. The truck pulls hard all the way to redline. I seriously do not feel the loss of torque at the lower RPM's like it's been said on dyno videos.

I will be taking notes over the next few weeks before I give my final thoughts on this mod. So far it was worth the +-5 hrs of labor and a 12pk we spent making it work.

Looks good but, what about the missing 5 cubic inches?

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