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I have an 04 Screw 4X4 5.4 3.55 and I get a whopping 13 mpg. I recently ran into a guy with an f150 screw 02 or 03. We got to talking about mods and mrg and such, and he informed me that he gets 20 mpg!!! The way that he supposedly achieved this was with the following: true dual exhaust, a more racing type air intake (rather than the boxed off area of the engine compartment, the spot where the filter goes is a large cylinder), and what he said made the biggest difference was his dual electric fans. I would me more than happy to figure out how to do this if it meant a significant mileage diff. I considered whether the difference in weight may factor in, but to counteract my 4X4 weight, he had a 4-6" lift kit also. Please analyze these claims and let em know your opinions!
The electronic fans, from what I have heard/read, make a signifigant difference in mileage. They free up the parisitic horsepower loss by getting rid of the belt driven fan.
Now as far as the intake and exhaust go, thats "iffy". Some say they got MUCH better mileage with intake and exhaust, some say it didnt do anything at all except change the sound of the vehicle.
I would say look into underdrive pullies and electronic fans for the best MPG increase. Also make sure your tire pressure is correct, or maybe even a little high. I increased tires pressure on my truck because I do alot of highway miles.
Also, if you do drive alot of highway miles, look into a tonnoue cover for the bed. Almost everyone I have heard from says they went up in MPG with the bed cover.
And slow down on the highway also, going 75 MPH doesnt get you there much faster than 65MPH.
From what I've heard the 3V 5.4 falls on it's face with a true dual exhaust system. It did wonder's for my 88 Bronco with the 351, but the 5.4 needs the back pressure to maintain the low end torque. No doubt the electric fans should help, but if they help that much I get your fan clutch checked first. It should only be turning the fan at 40-50% of the engine rpm's unless it's really hot out or you are working the engine hard towing.
Before you do any of this....have you had it back to the dealer for a EMM(electronic management modual) Reflash??? Seems to me there are more Screw guy's complaining about mileage then Scab or Reg cab trucks. My Lariat Scab get's 15-16mph in town no matter how I drive it and I've seen as high as 20.5mpg on the Garden State Pkw even with all the toll booths. I averaged 16.9mpg towing the 3000lb boat/trailer package on 900 mile(total) trip to NC last month. Actually it pulls the boat at 17.8. The 150 miles around town without the boat pulled the average down. 3.73LS.
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