Overview:
The Ford AIS system is a factory-produced and approved replacement intake system originally designed for severe service commercial and personal use. At its heart is a revolutionary disposable filter that not only flows extremely well, it can hold an absolutely enormous amount of dirt before it requires replacement. I chose the AIS system for my truck for several reasons:

1. It is a factory-designed and approved part, and maintains factory warranty coverage with no questions asked.
2. It will flow considerably more air than the stock system, and flows comparably with most aftermarket systems.
3. There have been many reports of the original air box leaking, allowing dirt and grit into the turbocharger and engine.
4. Some types of aftermarket “oiled” type filter elements can allow small dust and grit particles past, which can still damage the turbocharger.
5. Most aftermarket intake systems use an element sitting wide open in the extremely hot engine compartment, with little or no protection.
6. Most open-element intake systems produce a lot of additional under hood noise. While this may be acceptable for some, I didn’t really want the increased noise.

Tools Required:

1. 8 or 10 mm wrench, depending on which battery connections you have
2. 8mm socket
3. 13mm socket
4. Socket extensions (A 3” extension is pretty mandatory, if you have additional extensions, it can only make it easier)
5. Flat-head screwdriver

NOTE:
These instructions MAY work for “early” 1999 vehicles, however, while I’m not sure of the differences, I do know that a new air cleaner hose is required to install this system into an “early” 1999 vehicle. This hose is available from Ford.

Procedure:

1. Remove both cables from the driver’s side battery and the negative cable from the passenger side battery with an 8 or 10 mm wrench (depending on your battery connections). For additional safety, it is prudent to bag and tape the end of the positive cable to prevent an accidental short circuit, and the resulting fireworks display. You may also wish to tape over the battery terminals to prevent any tools from accidentally causing a short circuit as well. At this time, you can also remove the air cleaner cover and air filter by releasing the clamps on the filter cover and loosening the band clamp on the air cleaner hose with the flat-head screwdriver. If your Filter Minder has an electrical connector, (some years do not) remove that as well. Set them to the side.
   
2. Remove the battery cover. It is attached with 4 snaps, near its corners. Pull up near the front 2 snaps and the rear 2 should release as the cover tilts upward.
   
3. There is an 8mm bolt at the front of the battery for the battery hold down clamp. Remove this bolt and lift it, the clamp will come out with it.
   
4. Carefully lift the battery straight up, and out of the vehicle and set it aside.
   CAREFUL! The battery is heavy and contains acid. Do not excessively tilt or drop the battery. Use an assistant to help you if you need it.
5. Where the battery was sitting are 4 13mm bolts. Remove them and set them aside. You WILL need them later!
   
6. On the rear side of the air cleaner housing is air temperature sensor. Depress the tab on the plug, and remove it.
   
7. Remove the entire battery box/air cleaner base assembly in one piece. Lift up on the rear of the assembly, and slide it toward the rear of the vehicle to pull the “snorkel” attachment at the front from its hole in the radiator core support. Set the assembly aside.
   
8. Install the metal battery tray included with the AIS kit. It uses the same 4 mounting bolts that you removed in step 5. Keep all 4 bolts loose until you have all 4 started by hand. Don’t force the bolts, it is very easy to cross-thread and ruin the speed-nuts they thread into.
   
9. There are 3 speed-nuts included in the AIS kit. These are placed into 2 holes on the driver’s side fender and one on the battery tray as indicated in the picture below. If you are unsure of a mounting location, you can test-fit the AIS air cleaner lower housing to see which holes the mounting points line up with.
   
10. The AIS kit includes a new longer “snorkel”. Place it in the engine compartment as shown below. Be sure the word “TOP” is visible on the top of the snorkel otherwise it will not fit correctly. It should lie just to the inside of the battery tray, as shown. The front of the snorkel should stick into the hole in the radiator core support that the original snorkel used.
    
11. Install the AIS kit lower air cleaner housing into the vehicle, just to the rear of the new battery tray. Maneuver it and the “snorkel” into position so they snap together as the housing is lowered into position. An assistant is handy for this.
    
12. Using the 3 8mm bolts supplied with the AIS kit, fasten the lower air cleaner housing to the vehicle using the 3 speed nuts you placed earlier. As with the battery tray, start all 3 bolts by hand so you do not cross-thread them, and keep all bolts loose until all bolts have been started. Tighten them snug, but not too snug, as they are rubber-mounted, and over-tightening can damage the mounts.
    
13. Attach the temperature sensor cable to the temperature sensor on the AIS unit. It is in virtually the same place as the original one, on the rear of the housing.
    
14. Drop the filter included in the AIS kit into the housing. It only fits one way, and has “FRONT” molded into it for reference. Place the AIS kit housing cover on the lower housing assembly. Ensure it is aligned correctly, and secure the 4 clamps on the cover.
    
15. Slip the air cleaner hose onto the outlet of the assembled AIS housing and tighten the band clamp on the air cleaner hose with the flat-head screwdriver.
    
16. If your original Filter-Minder had an electrical connector, remove the protector on the AIS Filter-Minder plug and plug the electrical connector in. If yours did not originally have this connector, leave the protector installed.
    
17. Place the battery onto the new battery tray, with the battery posts toward the front of the vehicle. See the caution contained in step 4 with regards to the battery. A new battery blanket is supplied with the AIS kit. Slip it over the battery, with the cutout down and facing the front. Tip the battery slightly toward the rear of the vehicle, and using the original battery clamp, install the clamp as shown in the picture below. Start the clamp by hand and don’t force it to prevent cross-threading. Once it is started by hand, tighten it snug.
    
18. Reattach the positive and negative battery cables on the driver’s side battery and the negative cable on the passenger side battery. Tighten the clamps.
    
19. Double-check to ensure you completed all the steps and admire your work. The completed assembly is shown below. Start the vehicle, and take it for a test drive to ensure everything is functioning correctly. Congratulations! You now have a state-of-the-art air cleaner assembly for your Super Duty!
    

By Nate Elkins, used with permission