Airbox mod with cold air intake for 4.0L V6

[NHarris]

Intake Mod 4.0L V6

So I am making a cold air intake for my 2005 4.0L V6 X. I am keeping the stock airbox, as I do not want to mess with the MAF sensor. So far here's the pictures. I have the airbox mod done, and am getting a k&n filter.
Credit goes to MillerTimeX17 who decided to create a intake for his X and I am making a similar version using the stock airbox. See thread: first post in a long time
So far this has cost me $37 without tax.
So on to the pictures. Its not finished just yet...

So first...for you all who haven't seen the MAF on your explorer here it is:

Stock tubing compared to the new tubing. Not aligned correctly for the airbox.

Here's the new tubing in the airbox. This is not a finished product just yet.

There's my next problem to solve. A small gap... see what I can find to get that solved (my second gen X blurry in the background )

Tell me what you think of this. Any suggestions/comments welcomed.

 

[NHarris]

Update...Problem solved.

Well here's the finished product. Its well worth it. At 30mph I'm getting 19-20mpg, up from my 16-18mpg. I had to do some modification to get it to fit, but it is a working system now. Any questions I'll answer.

The gap was fixed by inserting a coupler in to the airbox and the pipe clamping the top (don't know if that helps)
Let me know what you think? Questions, comments, post em up.

 

[kstrayhorn]

Any noticeable power gains? and IMO, you should def. paint that blue piece black.

 

[CALDWELL]

Nate, this is awesome dude !!!

the only part i dont understand, is what you used to get the pipe and the maf housing sealed up ?

you showed a pic of a reducer coupling, buy the blue silicone hose ? im just curious what you may have had to do to seal the gap up...

 

[NHarris]

To seal off the intake I modified one of these couplers by slightly cutting it down (approx 1" cut-down)

I took out the black piece ignore that. To seal it off the airbox exits to the intake, is approx 3.5" (if I remember right), the pipe is 3" and the coupler fills in the .5" gap.
-First off... I could not find a reducer, so I will delete that picture of the reducer.
-Instead... I bought the blue coupler (pictured above) and cut the coupler down and cut the intake pipe down about 1" so it will fit better.

--As you can see the angle of the piping entry is slightly different from the angle of the airbox.
--With this 60 degree angle elbow I had to modify that piece of piping that goes in to the airbox by cutting the intake piping at an angle to compensate for the angle of the airbox. I cut about 1" off, sanded to make sure no debris gets sucked in the engine, and wiped it out.

--So after I cut down the piping I placed the cut-down coupler on the pipe and placed the piping with the coupler inside of the opening to the airbox. I used two hose clamps one on top of the airbox (not sure if it does any good there), and one on the piping to keep it in place. It seems to work so far.
--After that the TB piping with the vacuum hose piping and elbow piece were then connected to the airbox piping to create one unit.

kstrayhorn...
--Yes, there most definately is power gains. Much better acceleration, and gas mileage.
--The reason I went for the blue coupler is that was all autozone had left on the shelf.
--And the blue coupler does help with explaining how this mod is done

The total cost for this is:
$50 for parts
$54.99 for a K&N filter

 

[NHarris]

Possible problem and fix

--Just found this and wanted to alert all of you. Where the coupler joins the airbox there is a problem with it sealing off. It seals but anything hitting it can cause it to flex creating a gap. Problem is solved with another piece from that coupler.
--The black insert that goes inside of the coupler, place that back in to the coupler and then you're good to go!
--This isn't too much of a problem as it is a safety net. I don't want me, or anyone else to get dirt and other stuff in their engine.

 

[CALDWELL]

so basically if you buy this coupler, keep the inner piece, and reinsert the inner ring into the coupler, and you will have a good seal...


i going to try and see if i can find a 4'' to 3'' coupler, and see how that works first...

 

[NHarris]

Yep.
Thats what I am eventually going to buy. I couldn't find any reducers in stores, so I'm going to look online to see what I can find.

 

[GreenEyez]

So from the looks of it are you running a cone filter? The point of the new piping is for better air flow? or is it needed for the filter sorry I love what you did but I'm a little confused.

 

[NHarris]

--Currently I'm running the new piping into the stock airbox which has an airbox mod done to it. I bought a High-flow drop-in filter, and thats being shipped here. It still seems to sound quiet but there is a BIG difference in acceleration.
--It creates smoother airflow. The problem with the stock intake is the resonators to quiet the intake. That disturbs the flow of air.
--Now with the new intake I have more acceleration and better throttle response, yet I have better gas mileage. Went from 16mpg to about 19mpg

I just bought the reducer coupler. My local O'rielly auto parts store couldn't get it in so I bought it on their website.
I bought the 4"-3" coupler. Hope it works

I need to adjust the vacuum line part of the intake, or do something to make sure that vacuum hose stays in place

 

[GreenEyez]

I understand now I've never really ripped up my intake to see the guts. What kind of pipe did you use? Do you know what years have the air senor on the tube and what have it on the box?

 

[CALDWELL]

GreenEyez

02-03 4.0L Explorers have the seperate MAF piece...

* 02-03 explorers do have a K&N Intake Kit available...

04-05 4.0L explorers have the factory Airbox, and MAF as a combined piece...

 

[GRNMACHINE]

George @ Spectre was awesome in helping with parts needed for different apps.

 

[CALDWELL]

do you have an email address for this George fella ? or is his email address on the spectre website ?

the computer im on cannot read the website images etc etc...

 

[NHarris]

--All new piping is 3" piping from my local autozone store. The stock intake (at least on the 04-05's) starts at 4" and I think goes down to 3" at the TB.

 

[GreenEyez]

I'd like to keep the stock box I want to switch over to a snorkel eventually so I don't plan on dropping the money for a full intake Just a filter maybe new tubing and a slight airbox mod. Can always buy a new stock box when I do the install.

 

[NHarris]

Uh...you sure about buying a new stock airbox? Motorcraft quotes $297.00 for a new airbox. You have to get the airbox with the MAF. Go to the junkyard if you want a new stock airbox.

Motorcraft/Ford Parts Intake Box, 03 Ford Explorer

For us with 05's they want $305.80

05 Airbox Ford parts

 

[drothgeb]

I'm a little confused about how this is a cold air intake..? What did you do to modify the airbox?

 

[NHarris]

See3rd Gen Airbox Mod thread. That'll answer your questions. The airbox acts as a heat shield. The reason the airbox is still on there is the MAF is attached to the airbox.

Caldwell....
Looking at that thread, I think I need to drill some more holes in my airbox. I barely have half of what you have on your X.

 

[GRNMACHINE]

Danny 2, I believe I reached him thru Spectre email. Let me look for his email address. The guy was awesome in helping me find the exact intake parts for my Pathfinder.