4.0L Custom Intake

[CALDWELL]

Hey fella's !

As you guys know, in 2004 FORD basically screwed us over with any chance of an aftermarket intake...

so Icecube498, and myself. made a custom intake for our 3rd gen models. its not a true complete open cone system, but never the less its a much better improvement over factory. since the 06-10 4.0's have similar engine bays to the 3rd gen model, i thought i would extend 2 write ups that i made for the 3rd gen forum, and post here as well...

now with any performance modification, for optimal gains a tune will be required...

below im posting the " Stage 1 - Airbox Mod ", and the " Stage 2 - Intake " write ups i made...

Stage 1

http://www.explorerforum.com/forums/showthread.php?t=278734

Stage 2

http://www.explorerforum.com/forums/showthread.php?t=296439

hope this helps some of you 4th gen boys with are unfortunate intake problem...

Danny

 

[NHarris]

Caldwell, if its alright with you, I'll post up a pic of my intake...
I have a open filter "stage 3" intake. My X is a 2005 XLT V6
I basically bought the cheapest 02-03 Explorer intake ($30.00) I could find. I bought a filter and a MAF sensor housing to make this work.
EDIT: Here's the new photo:

There's a story behind why my MAF sensor wires are like that...
I tried another sensor to utilize the kit, but didn't work...so its the way it is.

 

[airplane mech 22]

That looks good, Here's mine on an 06 model

 

[NHarris]

That looks good, Here's mine on an 06 model

The 4th gens have one thing better in the engine bay than the 3rd gens...The radiator coolant reservoir is up front so you have more room for an intake. My intake is right up against the overflow hose.

Airplane Mech; I definately like the intake, isn't it amazing what a little injenuity can do for modding? We all with 04+ 4.0's were hit with a challenge of the combined MAF with airbox, and we're over coming it to make an intake.
What did you do for your MAF sensor, I can't tell on the pic.


Thanks caldwell for getting us (at least me) started on an intake!

EDIT: I honestly think this thread should be a sticky for this section..

 

[airplane mech 22]

They sell the MAF adapters at autozone but they don't fit the explorer. It comes with three types of adapters, use the biggest one.
1. Screw the adapter and gasket to the intake tube
2. use the edge of a file to make the adapter wide enough for the Sensor. ( it should be about 1/4 an inch on either side)
3. put the adapter on the tube facing the correct direction
4. Buy a tube of Permatec Sensor safe gasket maker and slather it on there, ( it should be blue, they have it at autozone)
5. put one end of the tube on your hand and the other on your mouth suck in until you can't hear air getting past the sensor. *(There probably are some health risks to breathing in that stuff but I was fine)*
*****give it 4 hours to dry otherwise you'll run lean and have to seal it again


Altogether it took me about an hour and a half, way better sounding exhaust now.

There is some blue stuff between the filter and the clamp, thats the permatec. I put on the bottom side because it looks messy. And here's the other in case anyones curious.

The tube that the kit comes with is too small. Use the Stock tube. On the small peice on metal coming off the air intake use 3/4 an inch of small tube and clamp the original tube around that. If you don't the seal won't be airtight and you'll run lean.

 

[NHarris]

Alright, good deal then.
I bought a Spectre MAF sensor adapter from Caldwell, it fit my MAF sensor perfectly. Its an online only type of item. Speaking of that crankcase fresh air hose, I need to buy a new one, I cut mine shorter to fit

Only complaint was a garffed up thread but thats what a rethreading kit is for

 

[CALDWELL]

glad to see members are over coming the issue of not having an available intake made for us

 

[nh5]

http://www.kustomz.com/054004.html

KKM has a intake for 04-10 4.0's. There's no point of replacing the upper part. Your not gonna gain a thing.

 

[CALDWELL]

KKM vs. Custom...

KKM is just a filter, and housing adapter thats over priced...

Custom - you get the KKM set up, plus ditch the restrictve factory tubing / resonators for the same price if not cheaper...

theres quite a difference...

 

[airplane mech 22]

kkm is $135 I spent $90 to replace everything. Replacing the factory tubing not only increases performance,but it also makes your exhaust louder and deeper.

 

[NHarris]

kkm is $135 I spent $90 to replace everything. Replacing the factory tubing not only increases performance,but it also makes your exhaust louder and deeper.

KKM and K&N are really expensive A cheap autozone kit or a cheap intake kit will do the same and be a lot better (on the wallet). My Intake was about the same in price

 

[jasons024]

has anyone tried ditching the k&n for the AEM dryflow with these set-ups. I had a catch can on my cobalt ss after my k&n and couldnt beleive what i got in it. I ditch the k&n with-in a month for the dry flow and hydra shield. but my filter area (in wheel well) wa smuch less prone to debris then where i would run it now. thoughts?
also has anyone thought about getting creative with the dremel and just chopping away at the maf to box (lid) vs fabbing a kit one or buying the KKM? might not be too pretty but seems like a ok (cheap) option.

 

[east1la]

Hey fella's !

As you guys know, in 2004 FORD basically screwed us over with any chance of an aftermarket intake...

so Icecube498, and myself. made a custom intake for our 3rd gen models. its not a true complete open cone system, but never the less its a much better improvement over factory. since the 06-10 4.0's have similar engine bays to the 3rd gen model, i thought i would extend 2 write ups that i made for the 3rd gen forum, and post here as well...

now with any performance modification, for optimal gains a tune will be required...

below im posting the " Stage 1 - Airbox Mod ", and the " Stage 2 - Intake " write ups i made...

Stage 1

http://www.explorerforum.com/forums/showthread.php?t=278734

Stage 2

http://www.explorerforum.com/forums/showthread.php?t=296439

hope this helps some of you 4th gen boys with are unfortunate intake problem...

Danny

thanks for the information. I beingoking around, but no luck for my 2007 explorer v6. I may do this.