Complete How To: Supercharge 4.ol V6 Sohc - Mustang 05-10

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Mar 31, 2014
Okanagan, BC
**NOTE: PART 1 of 3 (30 image blog limit)

Haven't seen a build blog quite like this yet... so here is the "Complete How-To Supercharge the 4.0L". If anyone is interested in supercharging a 05-10 4.0L V6... this blog is for you.

This was a pretty simple build that I was able to achieve in about a full day's work (and achieved around +100hp). The cost of the Moddbox ran about $2200 and you can find it on ebay. I needed some injectors and tune after and was good to go :)

You can find the dyno sheet here: 05 Mustang 4.oL V6 w/ Moddbox Kit-Dyno Sheet
(Moddbox Install Kit, 47lb Ford Racing Injectors, #6NGK plugs, & a Salvage 94 T-Bird Supercharger)

Ok... here it goes:

COMPLETE HOW TO: Supercharge 4.OL V6 SOHC - Mustang 05-10

The following Installation Instructions apply to the 2005-2010 Ford Explorer Mustang 4.0L SOHC models.

You should read the entire instruction manual prior to proceeding with your installation.

It is important to familiarize yourself with the ModdBox Supercharger Kit installation. It is the responsibility of the installer to properly install the Supercharger Kit. To ensure safety and proper installation, ModdBox recommends that this product only be installed by a qualified professional with access to pneumatic tools and a strong familiarity with automotive service procedures.

91 or higher octane gasoline is required at all times.

You must use fuel of 91 octane or higher. If your vehicle is not currently running 91 or higher octane, you must run your vehicle till empty and refill with the required octane at least 2 times prior to installation.

Any previously installed aftermarket tuning equipment must be removed and the vehicle returned to an as stock condition before installing the supercharger.

Any equipment that directly modifies the fuel mixture or ignition timing of the engine can cause severe engine damage if used in conjunction with the ModdBox Supercharger Kit. This includes, but is not limited to ignition boxes, air/fuel controllers, OBDII programmers, and any other device that modifies signals to and/or from the ECU. Aftermarket bolt-on equipment such as underdrive pulleys may conflict with the operation of the supercharger and must be removed prior to installation. Use of any of these products with the ModdBox Supercharger Kit could result in severe engine damage.


EGR – Exhaust Gas Recirculation

HVAC – Heating Ventilation & Air Conditioning

IAC – Idle Air Control

MAF – Mass Air Flow

TPS – Throttle Position Sensor

Vac - Vacuum


Standard metric socket set

Hex key set

Various pliers

T-30 Torx bit

Fluid funnel

Oil pan

Flat head screw driver

Pneumatic or electric hammer drill

Crescent wrench

Utility knife

Shop vacuum

Rat tail file

Propane torch or similar heating device

Wire Strippers

Wire Crimper


Stock Intake Pipe & Air Box Reference Diagram


Stock Exhaust Gas Re-circulation (EGR) Reference Diagram


Throttle & Stock Intake Manifold Reference Diagram


Ignition Coil Reference Diagram


Belt Diagram Reference Diagram (Dark Belt Showing the ModdBox Orientation)



*several parts not shown. Refer to installation the product for more details.
ModdBox Supercharger Bypass Valve
ModdBox 255lph Fuel Pump
ModdBox 5.5.0 & 8.0 psi Supercharger Pulleys
ModdBox Quick Change Pulley Adapter
ModdBox Plenum Bottom Plate
ModdBox Plenum Top Plate
ModdBox Intake Manifold
ModdBox Stainless EGR Extension
Black Silicone Liquid Gasket
Moddbox 6PK Serpentine Belt


Note: The installation has been broken up into two parts: (1) the fuel pump installation, and (2) the supercharger install.


WARNING: Gasoline vapors are explosive!

Caution: When replacing the fuel pump, perform all work in a well ventilated area away from sparks or open flame. Eye protection and rubber gloves are highly recommended. Avoid inhaling fuel fumes.

If fuel is ingested, seek medical attention immediately. To avoid a fire hazard, disconnect the negative battery cable when instructed. Failure to perform any service or repair in a safe manner may cause serious personal injury or death.

Relieve the fuel system pressure. This can be done by a variety of methods. It is recommended that you remove the fuel pump fuse and start your vehicle. The engine will run, shutter, then stall. Remove your key from the ignition and re-install your fuel pump fuse.

Remove the negative battery cable. Secure it to the side of the battery to prevent any accidental contact with the negative terminal.


Gain access to your vehicle's fuel pump assembly as required (fuel pump is located under the driver side back seat). Use a vacuum and/or a brush and clean off the top of the tank. Disconnect your fuel lines and remove the retaining ring. Caution: Do allow dirt or deleterious substances into your fuel tank.


Remove the fuel pump assembly.


Remove the Stock Fuel Pump Filter.


Un-bolt the ground wire and remove the pump retaining cap.


Remove the bottom pump cover.


Unplug the Stock Fuel Pump and disconnect the Fuel Line. It is recommended to use the stock fuel line. Be careful not to damage the fuel line during removal.


Remove the stock fuel pump and dispose of it appropriately.


Cut the bottom of the Rubber Retaining Gasket so that it can be used as a sleeve for your new 255lph Moddbox Fuel Pump.


File or cut the Stock Fuel Pump Assembly Retaining Cap to accomodate the new 255 lph ModdBox Fuel Pump.


Re-assembly the Fuel Pump Assembly and install the new pump. Reuse the stock fuel line and the provided stainless hose clamp Caution. Do not forget to re-connect the ground wire.


Press the provided In-tank Fuel Filter onto the new fuel pump.


Remove the Stock Fuel Pump Electrical Plug. Install the provided plug for the ModdBox pump by splicing in the wires as shown. lug in the new Pump and replace the Fuel Pump Assembly and secure the retaining ring. Re-connect your fuel lines. Caution: Be sure the plug has seated securely. Failure to do so may require you to re-access your pump assembly for inspection.



Note: Prior to proceeding, you may want to test your fuel pump installation. If you choose to test the fuel pump installation, be sure to remember to disconnect your battery prior to proceeding. Disconnect TPS plug and Electronic Throttle Plug.


... see Part 2 of 3
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