How to Install the Roush Bronco R Series Kit

With nearly 50 years of experience working on high-profile customizations and performance builds, Roush has consistently put out phenomenal upgrades. The Bronco R Series Kit is no exception, living up to the brand's legendary reputation. If you're an off-road die-hard, this might be the perfect kit for you.

What's Included in the R Series Kit?

The R series kit is full of Roush Bronco parts that improve the performance and style of your ride. It includes:

• A High-Clearance Axle-Back Exhaust
• Five 17” x 8.5” Wheels
• An Air Induction System
• Rubber Floor Liners for the Whole Vehicle
• A Center Console Locking Vault
• Unique Graphics & Badges
• Off-Road Accessories

This kit is compatible with the 2.3L and 2.7L engines, the 2- and 4-door chassis, and all modern Bronco trim levels.

The R Series kit costs $6,750. Once it's installed, your Bronco will be an official Roush vehicle. The kit even includes a certificate and serial number to prove it.

These components each come with a factory warranty. However, an ASE-certified technician has to be the one to install the kit. If the kit isn't installed by an ASE tech, the warranty will be void.

Roush Bronco R Kit Installation

Despite the many components in this kit, installation is straightforward. While the R Kit can be installed by a dealership, doing it at home saves you money. You'll also get the satisfaction of working on your own ride.

Use these step-by-step instructions along with our video for a seamless installation.

Roush Bronco Axle-Back Exhaust System

This axle-back exhaust is built with the outdoors in mind. The T304 stainless steel construction significantly improves resistance to rust and corrosion. A high-clearance design keeps scratches and scrapes from boulders to a minimum.

The 3” mandrel-bent tubing improves exhaust flow over the stock system for reduced backpressure. This tubing is supported by a high-flow muffler, removing the factory muffler's restrictions. A removable black exhaust tip with a “ROUSH R” logo is also included.

Work Smarter Not Harder: You'll need to lift your Bronco to install the exhaust system. The same is true for the wheels. It would be a good call to swap out the wheels along with the exhaust to avoid lifting your ride twice.

Required Tools:

• Lift or Jack Stands
• ⅜” Ratchet
• Short Extension
• 10 mm Socket
• 13 mm Socket
• 15 mm Socket
• 18 mm Socket

Step 1: Lift Your Bronco

Lift your Bronco so you have sufficient space to install your new exhaust kit.

Step 2: Loosen Factory Muffler Clamp

Loosen the clamp holding the muffler to the over-axle pipe.

Pro Tip: Leave this clamp on the over-axle pipe to make installing the new muffler easier.

Step 3: Disconnect Muffler From Hangers

Pop the muffler hanger arms out of the insulators on the driver and passenger side with a hanger removal tool.

Pro Tip: If you're having a hard time getting the hanger arms out of the insulators, spray them with a little soapy water.

Step 4: Remove Factory Muffler

Twist and pull the muffler until it slides out of the over-axle pipe.

Step 5: Disconnect Bumper Wiring Harnesses (for Broncos with Rear Bumper Sensors)

Disconnect the wiring harnesses for the rear bumper sensors on the driver and passenger sides.

Step 6: Remove Upper Bolts from Behind Bumper

Remove the upper bolts located behind the bumper. There should be one on the passenger's side and one on the driver's side.

Step 7: Remove Tow Hook Bolts from Below Bumper

Remove the four tow hook bolts holding the bottom of the bumper to the bumper support. Two of these bolts will be on the passenger side with the other two on the driver's side. This may also mean removing your tow hook.

If you have the Outer Banks Bronco, you'll only have two bolts on the driver's side.

Note: After you remove these bolts, the bumper cover will come right off. Make sure you or a friend are holding the bumper cover.

Step 8: Loosen Hanger Bolts

Loosen the two 10 mm bolts securing the hanger to the bumper mount. Don't remove these bolts entirely.

Step 9: Flip Bracket

Slide the bracket forward and pull it out of the bumper mount.

If you have a 2.3L Bronco, flip the bracket upside-down and reinstall it with the hanger arm at the right side.

If you have the 2.7L Bronco, use the provided 2.3L hanger, and position the hanger arm to the right.

After you've flipped the bracket, slide the bolts back into the holes and tighten them down.

Step 10: Reinstall Bumper Cover

Position the bumper cover back in place and reinstall the bolts removed in Steps 6 and 7.

Reminder: If the bolts in Step 7 were holding the tow hook, don't forget to reinstall this as well.

Step 11: Install New Muffler

Slip the new muffler's driver-side hanger arm into the insulator and put the muffler's intake pipe into the over-axle pipe.

Then, push the muffler's passenger-side hanger arm into the passenger-side hanger insulator.

Step 12: Tighten Factory Muffler Clamp

Tighten the factory clamp securing the stock over-axle pipe to the new muffler.

Step 13: Install Exhaust Tip

Slide the remaining clamp onto the exhaust tip. Then, position the tip onto the muffler and snug up the clamp.

Step 14: Check for Leaks

Start your Bronco up and check the exhaust for leaks. If you find any, you'll need to reinstall the exhaust. These leaks can occur if the pipes aren't fully inserted into your Bronco.

Pro Tip: It's normal to see a little exhaust coming from a small drain hole on the muffler. But if there's an excessive amount, you'll need to reinstall it.

Wheels

You'll receive five exclusive Roush wheels, including the externally mounted spare. These are by far one of the biggest draws of this kit, offering a 17” x 8.5” profile with a +25 offset. The design of the wheel even allows you to re-use the original lug nuts.

These wheels do not come with tires. But, the stock tires should fit just fine as long as they came with the 17” factory wheels. Whichever off-road tires you choose, remember they will need to be mounted and balanced.

These wheels install the same way any wheel does. But in case you need a reminder:

Air Induction System

Roush's cold air intake kit uses a large-capacity, reusable air filter to increase the volume of clean air taken in by your engine. It also comes with a reusable pre-filter that isn't necessary, but it'll keep dirt and debris from building up on your main filter while you cruise through the backcountry.

The new induction system also works with Ford's air inlet water trap so your Bronco maintains its water fording capabilities.

While the filter has an increased surface area, there are no engine compartment modifications necessary. This makes installation very simple.

The induction system isn't CARB-certified yet. However, Roush is in the process of achieving 50-state legality.

Required Tools:

• ¼” Ratchet
• Short Extension
• 8 mm Socket
• Small Flathead Screwdriver

Step 1: Remove Factory Intake Lid Screws

Remove the four screws securing the factory intake lid.

You'll be reusing these screws, so keep them handy

Step 2: Remove Factory Intake Lid

Use a small screwdriver to release the tension clips holding the lid in place and pull the lid out of the intake.

Step 3: Remove Stock Intake Filter

Wiggle the stock intake filter free from the filter housing and set it aside.

Step 4: Install New Intake Filter

Seat the wide-mouthed side of the filter at the intake tube with the other side of the filter up at an angle.

Then, push the filter down to lock it in place.

Pro Tip: If you're going to be doing a lot of off-roading, make sure you install the pre-filter on the main filter before you swap it in. The pre-filter should wrap easily around the main filter without impacting installation.

Step 5: Install Intake Lid Seal

Push the provided intake lid seal into the groove around the lid.

Pro Tip: If you're having a hard time getting the seal to seat around the corners in one piece, cut the seal into sections.

Step 6: Install New Intake Lid

Push the new lid into the intake inlet until the tension clips pop into place. Secure the new lid with the four factory screws from Step 1.

Step 7: Apply Badging

Wipe the lid down with isopropyl alcohol to prep the surface. Then, peel the red backing off the supplied “Roush Performance” badge and stick it in the small indent on the lid.

Step 8: Check for Leaks

Turn your Bronco on and check for leaks around the airbox lid. If there are leaks, reinstall the lid seal.

Floor Liners

This kit comes with a full set of rubber floor liners to replace the mats in the front row, back row, and cargo area. These liners are molded to the curves and contours of your Bronco's floor for a perfect fit. They even have deep grooves and a lip that extends to the door jamb to keep your ride as clean as possible.

Step 1: Remove Stock Liners

Remove the stock carpet floor liners and set them aside.

Step 2: Vacuum Carpet (Recommended)

Now's the perfect time to do a little interior detailing and vacuum up any dirt, debris, or crumbs hiding under the stock floor mats.

Step 3: Install New Liners

Position the new liners in place in the front row, back row, and cargo area.

Center Console Locking Vault

The center console vault provides you with a safe storage space. The combination can easily be set and changed. The lock also operates entirely without batteries.

Required Tools:

• 10 mm Wrench

Step 1: Set Up Vault's Main Frame

Swing the arms of the vault's main frame up so they extend away from the bottom plate that has the red “FRONT” sticker on it.

Step 2: Position Vault's Main Frame

Slide the frame into the center console, bottom-plate first. The arms should extend up the sides of the storage space.

The edge closest to the red “FRONT” sticker will face the front of the console. If the sticker falls off or is missing, the front of the frame is the side with a straight edge. The side with the rectangular inlet is the back.

Step 3: Position Locking Top Plate

Open the vault door. If it's locked, the code should be 0 - 0 - 0 - 0 to start.

Insert the four studs on the top plate into the four holes on the extended sides of the main frame. Don't close the vault door yet.

Step 4: Attach Top Plate to Frame

Push the side plates as close to the console walls as possible. Then, thread the four retention nuts onto the four studs, attaching the top plate to the main frame. Make sure you tighten these nuts all the way down.

Pro Tip: Continue to push the side plates toward the walls of the console as you install the nuts. This ensures the most secure installation.

Step 5: Anchor the Vault

Install two of the four self-threading screws into the holes facing the console's back at the top of the vault's main frame.

Install the other two self-threading screws into the holes facing the console's front at the top of the vault's main frame.

Fully tighten each screw until they bottom out on the nut.

Step 6: Set Lock Combination

If it's not already, open the lid. Then, keeping the dial in the open position, insert a paperclip into the small hole facing the driver's side seat.

With the paperclip still in the hole, set the dials to your preferred combination. Once the numbers are set, remove the paper clip. Your custom code should now work.

Pro Tip: If your code didn't work, you may not have pushed the paper clip in far enough. Set the dials to 0 - 0 - 0 - 0 again, and give it another shot.

Bronco Graphics and Badges

There are a variety of graphics and badges in this kit that will help transform your Bronco into a Roush vehicle. These accents range from small to large and will be installed on the exterior and interior.

Included Graphics & Badges:

• Driver and Passenger-Side American Flag Graphics
• Jack Roush Signature Decal
• Hood Graphics
• Roush Banner
• Body Side Stripes (4-Door Only) - Includes Extra Decal for Keypad Option
• Roush Front Fender Badge Set
• Interior Roush Graphic
• Official Roush Performance Door Jamb Label

Important Note from Roush: Open and lay the graphics out flat for storage if they won't be installed within one week of purchase. If you don't do this, the graphics may take a permanent crease or begin to separate from their backing.

Vehicle Preparation Tips

While placement and application will vary from graphic to graphic, there are a few tips that apply across the board.

Wash Your Bronco - Wash your Bronco before installing the graphics and badges to ensure a proper application. If you try to apply the decals on a dirty surface, they won't stick properly and are likely to fall off.

Clean Off Residue - Once you've washed your Bronco, wipe the areas where the graphics will be installed with an isopropyl alcohol spray. This will remove any remaining residue. The areas you'll need to wipe for this kit are:

• Hood center
• Passenger upper side body
• Driver upper side body
• Upper windshield surround
• Front fender
• Dash
• Passenger door jamb

Use the Wet Method - Using a slightly soapy mixture (5 drops of soap to 1 liter of water) on the graphics and paint will make it easier to make adjustments and remove air bubbles. Start by removing the paper backing from the graphic. Then, spray the back of the graphic and the area where you're going to install the graphic with the mixture.

Keep in mind, if you aren't comfortable installing these graphics there's no shame in going to a dealership or shop to have them put on. The real shame would be getting stuck with a crooked banner across the top of your windshield for the world to see.

Off-Road Accessories

In addition to the main upgrades and components, the R Series Kit is packed full of extra equipment. This includes items like:

• Hood center
• Passenger upper side body
• Driver upper side body
• Upper windshield surround

The recovery kit features a weatherproof case, 2 D-rings with a 9,500 lb capacity, flashlight, work gloves, and a 25' recovery strap with finished loop ends and an 18,000 lb capacity.

While the hitch cover and license plate frame use standard installation practices, there's a trick to the key fob back covers. You'll need to use your Bronco's key to pry off the back of the fob (see below). Once you have the stock cover off, simply swap in the new one.

Keep Customizing Your Bronco

While Roush's kit provides a lot of necessities, there are some notable absences, like off-road lights. Read through our article about how to pick the best off-road lights to suit your nighttime trekking needs. Consider grabbing a Bronco suspension kit if you're interested in lifting your Bronco.

However you decide to personalize your ride, connect with us on social media and drop a picture for CJ's Garage Squad. We love to see how your build is progressing. Also, make sure to sign up for our newsletter to stay in the know about new Bronco parts and deals on mods!