The_Fireball
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Recently fitted a Roush kit to a 2017 GT, and while it was apart decided to also install the 2020 GT500 aluminium covers (M-6067-M52S) and oil separator (M-6766-A52). Big fan of going OEM, which was a big driver for going this route instead of other options out there. Figured I'd add some pictures and notes for anyone else thinking of doing this too.
Besides the covers and separator, I realised when I started the install that I'd need some studded cam cover bolts. These are needed to mount the separator to the cam cover, and are already present on the GT500 even if it didn't come with the separator. Frustratingly, this wasn't stated at the time when I ordered the parts, with the Ford Performance and reseller websites (LMR, AM etc) all stating that all you need to add the separator to a standard 2015-2017 GT or GT350 is the GT500 covers. More frustratingly, when I emailed Ford Performance techline about this (twice) a few weeks ago to ask if they were aware and ask for the bolt part numbers, I received no response at all. I've noticed today that FP have now updated their page to mention "Requires three W720840-S437 bolts from Ford dealer", so it would seem the message got through, but a response to the info and help request would have been nice.
Anyway, rant over, onto the pics/guide:
The cam covers fit as usual, and are a direct replacement for the original plastic ones. Three of the original bolts need leaving out, so that the studded versions can be added:
As I didn't have the stud part number at the time, I had to improvise. The parts guy at the local Ford couldn't get the GT500 up on the system to look up the studded bolts, as it's not sold over here in the UK. Instead I went for some similar looking bolts from a transit diesel cam cover, and figured some customisation might be needed.
They were a bit too long and the thread wasn't going to engage the entire threaded part of the head. Using a tap and die kit I extended the threads, then used a Dremel to trim the bolts down a bit. Here you can see the original bolts, and the modified bolt after the tap and die (they're not trimmed in length here though). The thread looks a bit rough in the photo, but the thread was stable and pulled in well even with a few fittings.
Once these were in, the frame could be mounted and it was business as usual. I just needed some nuts for the top as the set applied with the separator were too small due to using custom bolts.
I won't post the separator fitting steps as others have covered that and Ford provide these online.
The next challenge is the PCV pipework. The standard 2020 GT500 PCV purge hose fits around the front of the Supercharger, where as the 2015-2017 Roush has the fitting around the back, as well as a return hose in the rear middle of the Supercharger. The standard Roush pipework is like this (taken from the Roush installation guide):
As the output from the separator points towards the front of the engine, the PCV pipe needs to turn 180 degrees to go back to meet that T junction. I tried some flexible Aeroquip fc598-10 pipe which was pretty stiff and vacuum rated (although this is always taking pressure out of the crank case), but to get it to turn that sharply without kinking wasn't really possible without a very wide arc.
To make it look as OEM as possible, I instead heated up some of the original factory hard plastic PCV hoses, to remove the connectors and reuse one of the pipes that looked like it'd fit. With the pipes warmed up was able to refit the factory pipe directly to the Roush T piece and a factory 90 degree fitting. As this brings everything closer to the Supercharger, I then opted to use the Aeroquip pipe for the short 2" piece needed from the T piece to the inlet plus some clamps:
Due to being mid-Supercharger install, the K brace wasn't fitted at this point, which helped a lot with the fitting too.
Hope that helps someone else looking at fitting these parts with a Roush install. Happy with the final result, no excess pressure on any of the connectors and no leaks, plus the factory fit look!
Besides the covers and separator, I realised when I started the install that I'd need some studded cam cover bolts. These are needed to mount the separator to the cam cover, and are already present on the GT500 even if it didn't come with the separator. Frustratingly, this wasn't stated at the time when I ordered the parts, with the Ford Performance and reseller websites (LMR, AM etc) all stating that all you need to add the separator to a standard 2015-2017 GT or GT350 is the GT500 covers. More frustratingly, when I emailed Ford Performance techline about this (twice) a few weeks ago to ask if they were aware and ask for the bolt part numbers, I received no response at all. I've noticed today that FP have now updated their page to mention "Requires three W720840-S437 bolts from Ford dealer", so it would seem the message got through, but a response to the info and help request would have been nice.
Anyway, rant over, onto the pics/guide:
The cam covers fit as usual, and are a direct replacement for the original plastic ones. Three of the original bolts need leaving out, so that the studded versions can be added:
As I didn't have the stud part number at the time, I had to improvise. The parts guy at the local Ford couldn't get the GT500 up on the system to look up the studded bolts, as it's not sold over here in the UK. Instead I went for some similar looking bolts from a transit diesel cam cover, and figured some customisation might be needed.
They were a bit too long and the thread wasn't going to engage the entire threaded part of the head. Using a tap and die kit I extended the threads, then used a Dremel to trim the bolts down a bit. Here you can see the original bolts, and the modified bolt after the tap and die (they're not trimmed in length here though). The thread looks a bit rough in the photo, but the thread was stable and pulled in well even with a few fittings.
Once these were in, the frame could be mounted and it was business as usual. I just needed some nuts for the top as the set applied with the separator were too small due to using custom bolts.
I won't post the separator fitting steps as others have covered that and Ford provide these online.
The next challenge is the PCV pipework. The standard 2020 GT500 PCV purge hose fits around the front of the Supercharger, where as the 2015-2017 Roush has the fitting around the back, as well as a return hose in the rear middle of the Supercharger. The standard Roush pipework is like this (taken from the Roush installation guide):
As the output from the separator points towards the front of the engine, the PCV pipe needs to turn 180 degrees to go back to meet that T junction. I tried some flexible Aeroquip fc598-10 pipe which was pretty stiff and vacuum rated (although this is always taking pressure out of the crank case), but to get it to turn that sharply without kinking wasn't really possible without a very wide arc.
To make it look as OEM as possible, I instead heated up some of the original factory hard plastic PCV hoses, to remove the connectors and reuse one of the pipes that looked like it'd fit. With the pipes warmed up was able to refit the factory pipe directly to the Roush T piece and a factory 90 degree fitting. As this brings everything closer to the Supercharger, I then opted to use the Aeroquip pipe for the short 2" piece needed from the T piece to the inlet plus some clamps:
Due to being mid-Supercharger install, the K brace wasn't fitted at this point, which helped a lot with the fitting too.
Hope that helps someone else looking at fitting these parts with a Roush install. Happy with the final result, no excess pressure on any of the connectors and no leaks, plus the factory fit look!
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