AFE Stage II Intake & Pro-Guard Filter Installation

October 30, 2005
Written by: E. Long
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AFE Stage II Intake


This article shows how to install an AFE Stage II intake with a Pro-Guard filter. This "how to" article was performed on a 2000 Ford Excursion with a 7.3L Powerstroke. The concept outlined in this article may also be applied to other vehicles, too.

AFE claims an increase of 50 horsepower @ 1900 RPM and 112 ft-lbs torque at 1900 RPM. The Pro-Guard filter is a washable/reusable filter.


Increase airflow, performance, and fuel economy by replacing the OEM intake & filter with an AFE Stage II intake and Pro-Guard filter.

Required Tools:

(1) 13mm wrench
(1) 5/16" socket
(1) 10mm socket
(1) 3/8" ratchet
(1) 5mm allen wrench
(1) Standard screwdriver

Purchase tools online from with your SuperMotors subscriber discount!

Products needed:

(1) AFE Stage II Intake Kit (Part # 54-10192 Stage 2 for 2000 Ford Excursion 7.3L Powerstroke)
(1) Pro-Guard 7 filter (Part # 75-10192 for 2000 Ford Excursion 7.3L Powerstroke)

Time Requirements

60-90 minutes


2 out of 10 (1 being easiest, 10 being hardest)

Where to Buy

I purchased my AFE Stage II intake kit from

Step 1: Remove driver side battery & battery cover
(link to this step)

This step may vary for you. I had previously installed an Optima Yellow-top battery and already had the battery housing removed. Please see this step for the procedure for removing your driver side battery.

Step 2: Remove stock intake
(link to this step)

a.) Disconnect air filter box clamps

Unclip the 2 clips on the air filter box and remove the intake from the filter box.

b.) Disconnect the air intake tube from the intake.

Install the retaining clips on each side of the battery prior to setting it into the tray. These retaining clips are a must as the Optima battery is significantly smaller than the OEM battery. The retaining clips provide the necessary extension for the battery to fit securely into the OEM battery tray.

c.) Remove the OEM intake tube.

Use a flat-edge screw driver to remove the fastener on the tube at the intake end.

Step 3: Remove battery tray
(link to this step)

a.) Remove 4 (10mm) battery tray bolts

Using a 10mm socket and 3/8" ratchet, remove all 4 battery tray retaining bolts.

b.) Remove temperature sensor

The temperature sensor is on the backside of the air box. Unscrew (turn left) and pull out. Tilt the battery tray up to gain access to the temp sensor. There is some slack on the temp sensor wire.

c.) Remove battery tray

Lift the backside (where the stock air filter is) of the tray up -- pull up and out to remove.

Step 4: Install AFE battery tray & battery
(link to this step)

a.) Install grommets

Install the two grommets (with small slits) into holes below on the AFE tray prior to installing the tray.

b.) Install AFE intake & battery tray

Install the AFE intake & battery tray -- line up the OEM battery bolt holes to correctly position the AFE tray.

c.) Install temperature sensor

Install the air temperature sensor through the small grommet on the back side of the intake housing.

d.) Fasten AFE intake & battery tray

Reuse 2 (10mm) OEM battery tray bolts for the inner fender bolt holes. Use the two supplied button-head bolts on the base of the intake housing (the black bolts). Use a 5mm allen wrench to fasten the button-head bolts.

e.) Reinstall battery

Install the battery. Use the supplied clamp and two 8" long hex head bolts and locking washers. Do not over-tighten.

Step 5: Install intake tube
(link to this step)

a.) Install coupler

Install the coupler onto the intake using the fastener and a standard screwdriver.

b.) Install intake tube

Insert the intake tube from the inside of the intake and battery tray. Be sure to install the fastener on the end of the intake. Using a rotating motion, insert the tube into the coupler and rotate into position. Line up the bolt holes on the intake tube flange with the holes on the intake tray. The flat side of the intake tube will rest against the foil-covered turbo pipe.

c.) Fasten intake tube

Tigthen the fastener on the intake tube on the intake side. Using the bolts, washers, locking washer, and nuts, install and tighten all 4 bolts around the intake tube flange.

d.) Install rubber grommet on the intake tube

e.) Install air filter minder

This is a tight fit. Use water to help insert the air filter minder into the grommet.

Step 6: Install air filter
(link to this step)

a.) Install air filter

With the fastener on the end of the air filter, install the air filter and tigthen the fastener.

b.) Reconnect battery cables & install trim seal on housing


This was a very straight-forward install and the parts fit perfectly. I notice better mid-range throttle response and acceleration. There is some additional in-cab noise with the new filter and intake, but the trade-off is well worth it.

Additional Questions or Comments?

Do you have additional questions or comments about this install article? Please discuss them in this forum thread.

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