Nutbuster

2002 Tacoma 3.4L

Took an hour to make this up out of Ford 6.0L Turbo diesel intake tube that go to the intercoolers...perfect size at 3" and they are mandrel bent. Air box is in stock location. Going to install the PCV crank case hose tomorrow as I had to pickup a fitting and extra hose...nice throtty sound and seems to run a bit smoother with a little more pep....see below for cheap sewer plug mod!

Nutbuster

No Marine shops around here that I know of for deck plate mod....

Sewer Cap Mod!

Your choice...3" or 4" Sewer Cap Plugs! ($2 or $3 at Lowe's) I went with the 4" as I plan on plugging up the factory inlet as it draws in nothing but dirty air that the tire kicks up....nice clean air up front...going to seal part of the right side of the hood at the fender to keep any rain water out...front hood is already factory sealed. We'll see how it does in the next rain storm. I may later add another 3" elbow to the factory pickup and run it back and inside for high water crossings, maybe not?!

Notice that I added the pcv hose to the inlet as well so it is complete...road test it tomorrow morning Fresh air sewer cap mod took about 30 minutes to do this in the garage. I used Marine Clear Goop to seal it in place...nice thing about these plastic pcv caps is that they have about 10 ridges where it glues in place...so I notched the factory air box so that it will not twist when the screw cap is installed. I cut the excess off at the threads, sticks inside the air box about 3/4" or so. Note: You want to make sure the main threaded body goes in fairly easy into the airbox so as not to distort the ring as the cap won't screw in easy.

BajaRunner

Nice job bud! Where you get that Ford intake from?

Nutbuster

I've been saving these up for a few years...as I work as a tech at a Ford dealership...I have a few for sale on the Pirate forum that I can part with....you can make two intakes from one pipe

PM me and I'll send you the link

mt_goat

Everytime I see these metal intake tubes I worry about where the flex is going to come from. The engine twists and moves quite a bit on its rubber mounts (try driving without your hood sometime and you'll be shocked how much it moves) and the stock corrugated rubber intake is there for a reason, flexablity. I'd be worried the plastic MAF tube will get ripped off the plastic air box, or the plastic air box mounts will break, I've seen both happen. Plus, I just don't see much (if any) benefit. It looks good though, hopefully there is enough give in those rubber couplings and yours won't break something. Good luck

I love the sewer cap mod BTW.

Nutbuster

Good Feedback mt_goat...I'll have to check that, I do have the orginal boots that came with the intercooler tubes that flex much easier than what I have on there...I'll have to do some power braking in both directions and see what it's doing...another thing is I could always just install one air box bolt at the Radiator support and let it pivot with the movement?!

mt_goat

That's probably a good idea.

Ron Helmuth

Great idea on the sewer cap instead of trying to use a deckplate-this will give you more room inside the airbox to attach a screen to filter out the bugs and so on.

Elvota

Wonder if you could support the intake some way off the motor only. You'd have to make sure the assembly would clear the fender or any fixed obstructions... but at least the intake and motor could "twist" together.

Just a thought.

On my older 3.0, I used some heavy PVC for the intake tube, and put sewer pipe rubber couplers at each end. Intake itself is hard mounted to the fender. I have run this setup for close to two years now without fail. Even though sewer coupling sound pretty ghetto, they are very thick and seem to flex well.



I later wrapped it with some header tape for no real reason except I had some extra header tape and time.

I also have a dual crawler setup... so the engine gets some good movement at time under load.

fillsrunner4

thats actualy probably a good idea never thought of that