ROUSH F-150 2021 User manual

ROUSH Performance
2021 F-150
SUPPLEMENTAL SERVICE MANUAL

2021 ROUSH©F-150 (5.0L)
Service and Diagnostic Manual
1121-01B001-AB
Revision History
-AA NEW 11/2021
-AB Added OEM exhaust removal and
ROUSH Exhaust installation
12/2021
Copyright © 2021 by ROUSH CleanTech.
All rights reserved.
The information in this publication was accurate and effective at the time
the publication was approved for publishing and is subject to change without
notice or liability. ROUSH CleanTech reserves the right to revise the information
herein and to make changes and discontinue production of described parts
at any time. CleanTech, LLC. All Rights Reserved.

2021 ROUSH Performance F-150 Service Manual
2021 ROUSH Performance F-150 Service Manual
Table of Contents
INTRODUCTION ............................ 1
CONTACTING ROUSH PERFORMANCE ........ 1
LIMIT OF LIABILITY STATEMENT.............. 1
IMPORTANT NOTE .......................... 1
VEHICLE SPECIFICATIONS ................... 1
ALERT MESSAGES .......................... 2
VEHICLE INFORMATION ..................... 3
Build Data .............................. 3
VEHICLE CARE ............................. 3
Interior Maintenance ..................... 3
Washing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installing a Front License Plate ........... 4
Attaching the Hitch Cover................. 4
EXHAUST.................................. 5
Disassembly of the Ford Exhaust .......... 5
Assembly of the ROUSH Off-Road Exhaust
(422266) ............................... 6
Assembly of the Optional ROUSH Active Ready
Exhaust Kit (422264)..................... 8
Assembly of the Optional ROUSH Active Exhaust
Kit (422265) ............................ 10
DECALS AND GRAPHICS..................... 14
Rear Window Signature Decal ............. 15
Tailgate ................................ 16
American Flag Graphic (above RH Tail Light). 16
Hood Stripe Decals (Left and Right on Hood) 17
Door Graphics........................... 17
WIRING HARNESSES ........................ 18
Grill Light Harness ....................... 18
Active Exhaust Wiring Harness ............ 19

2021 ROUSH Performance F-150 Service Manual
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2021 ROUSH Performance F-150 Service Manual
INTRODUCTION
This manual is a intended to be a supplement to the
regular Ford Workshop Manual for your 2021 ROUSH
F-150, covering most of the unique components that
were factory installed by ROUSH Performance onto
your vehicle.
CONTACTING ROUSH PERFORMANCE
For Service
For emergency situations or if immediate technical
assistance on your ROUSH Vehicle, please contact ROUSH
Performance Technical Support at (800) 59-ROUSH
(597-6874).
For Any Other Customer Service Needs
For non-emergency situations or to purchase additional
component for your 2021 ROUSH F-150, please contact
ROUSH Performance Inside Sales and Customer Service
at (800) 59-ROUSH (597-6874).
For Publications
For inaccuracies or omissions in our service publications,
or to provide general feedback or suggestions regarding
the quality of the information presented in this manual,
please contact the Publications Department in the ROUSH
Performance at [email protected].
LIMIT OF LIABILITY STATEMENT
All procedures, images, specications, or descriptions
have been veried and known to be accurate at time of
publishing. However, due to continual updates to our
products, procedures, and diagnostics, changes to this
manual may occur periodically. Updated manuals can be
found at www.ROUSHPerformance.com by clicking on
the Help button at the top of the page and the searching
for the manual. Each new revision will contain a "rev
number" in the box before the table of contents (ex.
1318-B0100-AA).
IMPORTANT NOTE
Before removing any ROUSH components, please read this
manual and verify that all items and tools are present. If
you are missing hardware or have any questions, please
contact ROUSH Performance at 1-(800) 59-ROUSH.
VEHICLE SPECIFICATIONS
Vehicle Weights
(in lbs.)
LF RF LR RR TOTAL
Canadian
Truck, no active
exhaust
1542 1601 1152 1100 5395
US F-150 with
Active Exhaust,
6 piston brakes,
center console
vault, and off-
road utility kit
1570 1589 1181 1173 5508
Vehicle Dimensions: Inches MM
Height 78 1981.2
Width (less mirrors) 83.6 2123.44
Width (mirrors extended) 95.7 2430.78
Track Width 81 2057.4
Wheelbase 145.4 3693.16
Overall Length 231.7 5885.18

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Fuel in the fuel system remains under high pressure
even when the engine is not running. Before working
on or disconnecting any of the fuel lines or fuel system
components, the fuel system pressure must be relieved.
Failure to do so can result in personal injury.
Do not smoke or carry lighted tobacco or open ame
of any type when working on or near any fuel-related
components. Highly ammable mixtures are always
present and can be ignited, resulting in personal injury.
STOP
STOP
CAREFULLY READ THE IMPORTANT SAFETY
PRECAUTIONS and WARNINGS BEFORE PROCEEDING
WITH THE REPAIRS!
Appropriate disassembly, assembly methods and
procedures are essential to ensure the personal safety
of the individual performing the kit installation. Improper
installation due to the failure to correctly follow these
instructions could cause personal injury or death. Read
each step of the manual carefully before starting the
installation.
Perform this installation on a good clean level surface
for maximum safety and with the engine turned off
• Always wear safety glasses for eye protection.
• Place the ignition switch in the OFF position.
•
Always apply the parking brake when working on
the vehicle.
•
Block the front and rear tire surfaces to prevent
unexpected vehicle movement.
•
Operate the engine only in well-ventilated areas to
avoid exposure to carbon monoxide.
•
Do not smoke or use ammable items near or around
the fuel system.
•
Use chemicals and cleaners only in well-ventilated
areas.
•
Batteries can produce explosive hydrogen gas which
can cause personal injury. Do not allow ames, sparks
or ammable sources to come near the battery.
•
Keep hands and any other objects away from the
radiator fan blades.
• Keep yourself and your clothing away from moving
parts when the engine is running.
•
Do not wear loose clothing or jewelry that can be
caught in rotating or moving parts.
•
Premium fuel (91 octane or higher) is required to
prevent “spark-knock” or detonation under certain
operating conditions.
•
The use of fuel additives (i.e. octane boosters) is
not recommended. There is a possibility that these
chemicals can damage your engine and cause
drivability issues with your vehicle and void your
warranty.
•
Operating your engine without the ROUSH PCM
recalibration will result in engine damage or failure
and will void your warranty.
• 5W50 oil is required.
ALERT MESSAGES
The following alert messages appear from time to time in the appropriate places in this manual. Ensure that all
personnel in the immediate area are aware of these reminders.

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2021 ROUSH Performance F-150 Service Manual
Exterior Maintenance
To protect your vehicle’s exterior nish and graphic
decals (if applicable), it is important to wash your vehicle
often. Industrial fallout, road tar, bird droppings, tree
sap, and other foreign matter can damage the nish on
your vehicle.
Washing
Before washing, rinse your vehicle with clean water
to remove any surface contamination. Next, wash the
vehicle from top to bottom using a soft sponge or wash
mitt with a mild vehicle wash soap. Finally, rinse the
vehicle thoroughly and wipe it dry with a soft towel or
chamois. To complete the job, carefully clean the door
jambs and joints between the doors, hood, and trunk of
your vehicle with a damp cloth. Never wipe a dry surface,
as ne scratches in your paint will result. The non-gloss
paint nish of the front exterior grille and bumper cover
should be handled carefully as excessive contact will
create smooth paint surfaces and effect gloss level.
NOTE:
ROUSH recommends hand washing your vehicle. If
your vehicle is equipped with decals, such as stripes,
do not use a commercial or high-pressure wand on
the striped surfaces or stripe edges. Damage resulting
from an automatic car wash or high-pressure wand is
not covered under your warranty.
NOTE:
• Maintain a minimum distance of approximately 16
inches (40 cm) between the vehicle body and the
wash nozzle.
• When washing around the door glass, increase the
distance to 40 inches (1m) and spray at right angles
to the glass surface.
Waxing
ROUSH recommends that you wax your vehicle at least
twice a year, or when painted surfaces do not shed
water well. Make sure your vehicle is clean and dry
before waxing. As with washing, do not apply wax in
direct sunlight.
Note: Do not get wax on any of the decals or graphics.
VEHICLE INFORMATION
Build Data
ROUSH Performance emissions certication information
is recorded on the ROUSH Performance Vehicle Emissions
Control Information (VECI) labels. The labels are vehicle-
specic and are required by law to be on the vehicle to
which it is assigned along with the Ford VECI label.
VEHICLE CARE
Interior Maintenance
Leather Seats
Real leather is not uniform and may have scars, scratches,
and wrinkles. To clean your leather, use a mild soap or
leather cleaner and wipe it with a damp soft cloth. Buff
the leather after cleaning with a dry, soft cloth.
Vinyl
Vinyl can be cleaned either with a mild soap and water
solution or commercially available products. At times, it
may be necessary to use a soft bristled brush to remove
stubborn stains or dirt from the surface.
Carpet
Vacuum the carpet frequently to remove dirt. Ground-in
dirt will make the carpet wear prematurely. Use a foam
type carpet shampoo periodically to keep your carpet
looking new. Follow the instructions that are supplied
with the cleaner but be careful to not oversaturate the
carpet as it may take an excessive amount of time to dry.
Setting the Console Safe Combination
1. The combination is factory-set at 0 - 0 - 0 - 0.
2. The combination must be on the opening number
prior to resetting.
3. On the underside outer edge of the lock, there is a
hole for the code reset button. Rotate the face of the
cam until the code reset button comes into view.
4. Push this pin in with a paper clip and keep it pushed
in.
5. Set your personal combination by turning the dials
to the desired combination.
6. Release the reset button and your new combination
is set.
7. To lock, rotate the lock to the “Locked” position.
Rotate one or more dials after the lock is closed.
8. Then, to open the lock, turn dials to your personal
combination.

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Fender Flare Maintenance
Periodically the trim on the fender ares may become
dislodged and will need to be slid back into place. For
vehicles with optional fender ares, ROUSH has included
a fender are trim tool in the glove box.
1. Use the supplied tool to seat the edge trim against
the vehicle by hooking the curved end of the tool
under one end of the are trim. Then, slide the tool
along the trim to the other side of the are.
2. Next, using the at end of the tool, seat the edge
trim against the are by inserting the straight side
between the edge trim and the are at one end of the
are. Then, slide the tool around the entire length
of the edge until you reach the other end.
Installing a Front License Plate
1. Reach through the opening of the front bumper cover
panel, align a pick tool in the center of the bottom
bosses on the front bumper cover panel. Using the
pick tool, push into the center of the boss to create
a locator hole on the outside face of the part. Repeat
this process for the other bottom boss.
2. Gather the license plate, fasteners, screwdriver and
power drill with a 11/64” drill bit.
3. Drill two (2) holes using a 11/64” drill bit at the locator
holes that were created in Step 1.
4.
Install the two (2) fasteners into the drilled-out holes
created in Step 3. Tighten the screw using a at-head
screwdriver until the license plate is fully secured.
Attaching the Hitch Cover
The ROUSH Trailer Hitch Cover is shipped in the glove
box of the vehicle. No hitch pin or clips are required to
install, the cover simply ts over the receiver tube for
easy installation.

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2021 ROUSH Performance F-150 Service Manual
EXHAUST
Disassembly of the Ford Exhaust
The following section will guide you through the disassembly and removal of the stock components.
1. Remove the two (2) bolts that secure the intermediate pipe and resonator to the catalyst pipe. Set these
fasteners aside as they will be re-used.
2. Loosen the clamps that secure the intermediate pipe and resonator to the muer and tail pipes.
3. Remove the hanger in the center of the vehicle at the rear of the muer. This will aid in removing and installing
the exhaust components.
4. Remove the intermediate pipe and resonator from the vehicle.
5. Slide each of the hangers out of the rubber hangers and remove the factory muer/tail pipe assembly from
the vehicle.
6. Cut front ange off catalyst ange here. Retain for later use.

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62021 ROUSH Performance F-150 Service Manual
Assembly of the ROUSH Off-Road Exhaust (422266)
The following section will guide you through the assembly and installation of the ROUSH components.
1. Loosen the rear spring support bracket bolt so that there is a gap of about 7-10 mm of threads showing.
2. Slide over the ange cut off during disassembly in this manual. Position the new catalyst pipe adapter ange
into place against the catalyst pipe and loosely install the two (2) takeout fasteners to hold it in place.
3. Position the new muer outlet axle pipe into position and install the steel hanger brackets into the factory
rubber hangers. Orient the pipe such that the ared end faces forward in vehicle. At this time, re-install the
hanger bracket that was removed in step 3 of the Disassembly section.
4. Insert one (1) 3" clamp over the outlet end of the new muer assembly and slide this into the end of the
muer outlet pipe. Position the clamp on the joint and loosely secure.
5. Remove the intermediate pipe and cut the pipe. Mark the pipe and double check BEFORE cutting to ensure it
will be cut correctly. Be sure to leave enough length for engagement into the catalyst pipe ange. Cut off the
end OPPOSITE the hanger that is welded to the pipe. Remove all sharp edges after cutting.
7. Re-install the pipe assembly to the catalyst ange. Loosely install the two (2) fasteners.

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2021 ROUSH Performance F-150 Service Manual
8. Install one (1) 2.5" clamp onto each of the exhaust tips and slide the tips onto the ends of the Y-pipe. Position
the clamps on the pipe joints and loosely secure the clamps.
9. Insert one (1) 3" clamp over the end of the new Y-pipe assembly and slide into position on the end of the
muer outlet pipe.
10. Insert the Y-pipe hanger into the hanger bracket. It is important to note the orientation of the bracket as it will
hang underneath the suspension bracket.
11. Slide the new rear tailpipe support bracket between the head of the bolt and the frame. Re-torque the bolt to
185 Nm. When torquing the leaf spring bolt, this must be done with the vehicle on the ground, not on a hoist.
The vehicle must be under its own weight.
12. With the full system now hanging in the vehicle, make sure all of the hangers are fully seated and there are
no clearance issues with vehicle parts contacting the exhaust system.
13. With the system in the desired position, torque all four (4) 3" clamp joints to 50 Nm (36.88 ft-lb).
14. Torque the two (2) catalyst adapter bolts to 44 Nm (32.45 ft-lb).
15. Torque the two (2) 2.5" clamps on the tips to 50 Nm (36.88 ft-lb).

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Assembly of the Optional ROUSH Active Ready Exhaust Kit (422264)
The following section will guide you through the assembly and installation of the ROUSH components.
1. Loosen the rear spring support bracket bolt so that there is a gap of about 7-10 mm of threads showing.
2. Install a hangar Install a hanger (1117-5A295) using the takeoff fasteners from the exhaust removal procedure
Place a rubber isolator on the hanger. Torque the fasteners to 25 Nm.
3. Measure 290 mm from the rear of the resonator. Cut and deburr the
outer edge of the pipe. Use the Y-pipe (PT00038556) to mark the
factory pipe as shown. (This will help with setting the Y-pipe in the
correct location on vehicle.).
5. Using the supplied gaskets (CV6Z-9450-C) and two (2) nuts
(NM8X125HF-S437), install the outlet adapter (1315-5232CPL). Torque
the nuts to 25 Nm (18.44 ft-lb).
6. Slide a 3" clamp (10-0439) over the Y-pipe (near the ex joint). Slide
a 2.5" clamp (10-0338) over the other two (2) joints. Install the Y-pipe
onto the factory resonator pipe as shown.
7. Slide the muer onto the Y-pipe.
8. Install the mid-bed isolator onto the bed. Torque to 25 Nm (18.44 ft-lb). (10mm Socket).
9. Raise the muer assembly and slide it into the hanger on the passenger side frame rail. Move the resonator
forward to line up the anges.

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2021 ROUSH Performance F-150 Service Manual
10. Tighten the bolts on the OEM Y-pipe ange. Torque to 40 Nm (29.50 ft-lb).
11. Slide the muer until it is positioned so you can see the mark made in step 4 of this procedure. Tighten the
clamps to keep the pipes from moving.
12. Install the takeoff hanger as shown onto the 3" over-axle pipe (PT00038892).
13. Install the supplied hanger (1115-5A204) onto the dual exhaust tip (PT00038638).
14. Slide a 3" clamp (10-0439) on the tip and slide onto over-axle pipe (PT00038892). Install the hanger onto the
passenger side frame rail with the over-axle exhaust pipe and tip attached.
15. Install the 3" over-axle pipe onto the muer and slide the hanger onto the leaf spring shackle bolt. Snug up
the shackle bolt so that the pipe is supported. Do not torque yet.
16. Align tips to your liking, and starting at the front, tighten the clamps making sure everything is aligned to 55
Nm (40.57 ft-lb).
17. With the vehicle on the ground, torque the spring shackle bolt to 235 Nm (173.33 ft-lb).

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Assembly of the Optional ROUSH Active Exhaust Kit (422265)
This kit is ONLY compatible with the ROUSH Active Ready Exhaust kit (422264).
The following section will guide you through the assembly and installation of the ROUSH Active Exhaust kit
components onto a vehicle that has the ROUSH Active Exhaust Ready kit (422264).
Installing the Active Exhaust Valve
1. Remove the 3" clamp (10-0439 in the image above) to separate the rear of the exhaust from the muer. Retain
all parts and fasteners.
2. Remove the LH and RH muer inlet pipes from the front-side of the muer.
3. Remove the muer from the vehicle.
4. Using the supplied gasket (CV6Z-9450-C) and two (2) nuts (NM8X125HF-S437), install the exhaust valve
(PT00042392) onto the muer (PT00038572) as shown.
5. Attach the rear portion of the exhaust onto the vehicle.

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2021 ROUSH Performance F-150 Service Manual
8. Install the supplied connector onto the WHITE with
BLUE wire. Connect the mating electrical connectors
together. Engage the red locking tab.
9. Plug the 12V and 110V connectors into the trim
panel and leave loose. (The switch can be installed
next to the power port if the vehicle does not have
the 110V power source)
10. Determine a switch location. Remove the panel and
drill a 20 mm hole. Route the wires to the switch. The
switch is fastened using a lock washer, you must
unplug the switch and install from the front of the
panel then plug in the switch.
11. Remove the fuse block cover and kick panel.
12. Locate the fuse tap portion of the harness. Remove
fuse #2 from the fuse block (You may have to
remove the green fuse at the top to ease in removal/
installation). Insert fuse#2 into the fuse tap, and
insert the fuse tap into the fuse #2 location on the
block.
13. Secure the harness (CTUV740) up under the dash
using the supplied zip ties.
14. Remove the zip ties that cover the OE wiring harness
that runs the length of the vehicle.
15. Loosen the B-pillar trim piece by pulling just below
where the seat belt comes out. Do not remove.
Installing the Active Exhaust Harness
NOTE: The active exhaust switch can be installed in
multiple different location. Wire lengths are longer than
needed for custom installations.
1. Remove the glove box.
2. Remove the passenger side trim panel.
3. Remove the passenger side rear pillar trim panel.
This is held in with clips.
4. Remove the two dash trim pieces by pulling rmly, a
plastic trim removal tool will help with this procedure
to not damage the trim. Remove the screws holding
the HVAC control plate to the dash.
5. Locate the connector for the 12V power outlet Using
a small pick, remove the red locking piece that is in
the end of the connector. Carefully lift the tab for the
WHITE with BLUE wire in the connector and remove
the terminal from the connector.
6. Locate the connector for the 12V power outlet Using
a small pick, remove the red locking piece that is in
the end of the connector. Carefully lift the tab for the
WHITE with BLUE wire in the connector and remove
the terminal from the connector.
7. Take the yellow lead from the active exhaust harness
and insert it into the spot in the 12V power outlet
connector that was de-pinned in the previous step.
Replace the red locking piece that was in the end of
the connector.

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16. Route the active exhaust harness along the outer oor
to the passenger rear corner of the vehicle. Route
the harness under the front scuff plate, behind the
B-pillar trim (under the seat belt bracket), under the
rear scuff plate, and behind the C-pillar trim.
17. Route the plug out of the rear cab vent.
18. The wire will run down in between the cab and the
bed of the vehicle. Pull the wire past the rubber seal
that bridges the gap between the cab and bed. Add
a zip tie to secure.
19. Plug the connector into the valve on the muer.
20. From inside the cab, pull gently on the wire until all
slack is taken up. Use a zip tie to secure the wire to
the wall of the cab. Zip tie the relay to the rear wall
of the cab.
21. Remove the ground and attach the active exhaust
ground to OEM location.
22. Reinstall all the trim panels that were removed in the
previous steps.
Quick Diagnostics for Valve Concerns
1. Unplug the valves one by one while having another
technician activate the switch on the console
approximately 5-10 times.
2. While the switch is being activated the other technician
should be verifying the proper movement of the valve
that is still plugged in.
This test will determine which valve is at fault and needs
to be replaced based on the one that does not respond
to the movement of the switch. If both are working
properly, please contact ROUSH Technical Support at
800-59-ROUSH.

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2021 ROUSH Performance F-150 Service Manual
FOX 2.0 SUSPENSION
Component Torque Value
Front Axle Nuts 40 Nm (29.50 ft-lb)
Front Wheel Speed Sensor Bolts 12 Nm (8.9 ft-lb)
Front Brake Anchor Plate Bolts 250 Nm (184 ft-lb)
Lower Ball Joint Nuts 103 Nm (76 ft-lb)
Upper Ball Joint Nuts 63 Nm (46.5 ft-lb)
IWE Bolts 12 Nm (8.9 ft-lb)
Brake Hose Bracket Bolts 30 Nm (22 ft-lb)
Tie Rod End Nuts 103 Nm (76 ft-lb)
Shock Absorber and Spring Assembly Upper Nuts* 33 Nm (24.3 ft-lb)
Shock Absorber and Spring Assembly Lower Bolts* 95 Nm (70 ft-lb)
Front Stabilizer Link Upper Nut 80 Nm (59 ft-lb)
Rear Shock Absorber Upper/Lower Bolts and Nuts 90 Nm (66.4 ft-lb)
* Denotes blue Loctite 242 is required.
Important Notes on Installation
Ride Height may vary based on truck conguration. Base chassis congurations and engines application will
affect nished ride height. Ride height can be adjusted to customer preference using standard coil over spanner
wrenches.
NOTE: Perch position is 63mm for this vehicle, which is a 5/8” down adjustment on the strut shaft (towards the
lower control arm) for proper suspension travel & improved ride (see below)

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DECALS AND GRAPHICS
All that is required to replace the graphics on your vehicle is a spray bottle with soapy water, a squeegee, and a
micro ber towel. Use a premixed solution of soap and water mixed in accordance with current specications.
Take special care when applying graphics over body lines to ensure all air pockets/bubbles are removed.

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2021 ROUSH Performance F-150 Service Manual
Application Instructions
Note: Graphics can only be ordered as a service item. Pictures of the previous graphics and the VIN of the
vehicle are required to purchase.
1. Clean area where the graphic will be applied with alcohol and wipe clean with a micro ber cloth.
2. Apply soapy water to the top of the graphic.
3. Use squeegee to lock the graphic into position. Tolerances for each graphic will be shown below or on the
following pages.
4. Peel paper off the graphic.
5. Use the squeegee to correct any air bubbles.
Windshield Decal
Note: ROUSH decal should not cover up any of the Ford decal on the windshield.
Nominal Gap = 7 mm ± 2 mm
Rear Window Signature Decal
Nominal Gap = 22 mm ± 5 mm
Nominal Gap = 67 mm ± 5 mm

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Tailgate
Nominal Gap = 160 mm ± 2 mm Nominal Gap = 170 mm ± 2 mm
Nominal Gap = 15 mm ± 2 mm
American Flag Graphic (above RH Tail Light)

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2021 ROUSH Performance F-150 Service Manual
Hood Stripe Decals (Left and Right on Hood)
Nominal Gap = 8 mm ± 3 mm
Nominal Gap = 4 mm ± 3 mm
Door Graphics
Nominal Gap = 30 mm ± 5
Nominal Gap = 40 mm ±5 mm