Most of you will recall this thread (now a sticky) about the ISR mod warping on 96 - 98 3.4's.

I finally found a permanent fix, and it looks better too!

There are two new parts:

1. 2" PVC cleanout plug (Lowes $.66)
2. 2" Hose clamp (any auto store)

Here is what the plug looks like (sorry it is upside down)


This is the inside (the side that will be exposed to the intake air)


With the barbed fittings in place...


After painting...


The end result:


It fits perfect!

I will get this supplemented to my 96 - 98 write-up.

 

so you have to drill the holes and use the jb weld stuff??

Hmm...looks like I'm gonna have to try and attempt this on my own this time.

 

No, you do not have to use JB Weld. If you drill the hole perfecly, there is no way air can "escape" or be sucked-in. JB Weld was just a safe gaurd.

I can always make one for you Rob, just let me know!

 

wow, good find 96 runner..hey if you get the final writeup done, i'd be interested in doing it since i doubt i am getting a supercharger now. also, if you could make me one i'd be willing to send some "donation" money your way..thanks!

 

Haha. thanks Christian. Well if you could just let me know what size drill bit, I should be able to make it using the drill here in our machine shop

 

Yeah, if anyone wants the full (and revised) ISR mod set-up, I will make it for $20 shipped to your door. That includes paint, clamp, parts...everything!

Just PM me.

 

sweet, you should be able to get those 2" cleanout caps in black so you dont need to paint them

 

Rob-

When I get home tonight I will check the drill bit size and let you know tomorrow.

 

That's nice looking work Christian!
Can't wait to revise the mod in my truck

 

Rob and others-

The drill bit size is 9/32. A deep socket will take care of the barbed fittings. No JB needed!

 

yea pulled my isr out today, you're right, it's warped as you can see here:



And these babies gave me extra 15 hp while I worked on the rig today



I tried to put my original intake silencer back on, but couldn't get it to fit in the hole, it's like the hole shrunk. Got kind of frustrated, so I just put the isr back in again.

I'll probably try to make a new one sometime this weekend or so.

christian where would I get the barbed fittings?

 

Cool gloves Rob!

Just put your stock box back in for the time being.

Check out my write-up, Corey has added a supplement to it.

You can get the fittings at Home Depot (probably Lowes too)

 

What did you do with the J shaped piece the was on the bottom of the intake nearest to the airbox. I was wondering cause i didnt see it this pic

 

I stayed with the plumbing end cap there. The fit is much tighter, and I found no warpage. Wouldnt hurt to go with a new 2" hose clamp there too though.