I just took the truck into the dealer and they loaned me a car while they try and fix the intake hose on the blower. They're working it out with Roush right now. I let them know I would be interested in the intercooler kit if it fixes the issue. ;-)

Apparently the Roush intake hose that comes on the '05 Roushcharger kits has a rubber intake hose gasket that's poorly designed. As the metal hose clamp wraps around the plastic intake hose, the rubber gasket can't be tightened enough and eventually the tube slides off and the engine runs lean, which throws a OBDII code. I told the dealer that putting a rectangular notch in the plastic intake hose should solve the problem, but they want to talk with Roush first on the best solution. Here's a shot of the intake hose:



I recommend that all Roushcharger owners periodically tug on their intake hose to ensure it's not coming loose. Otherwise you could run lean and possibly stall.

Will keep you posted.