94-97 Powerstroke DIY Intake - detailed instructions - Diesel Truck Forum - TheDieselGarage.com
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post #1 of 24 (permalink) Old 11-29-2006, 02:54 PM Thread Starter
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94-97 Powerstroke DIY Intake - detailed instructions

Parts needed: 1 Napa 6637 filter (Wix 46637) or equivelant, 1 constant torque clamp to fit filter (intercooler hose clamp), 1 piece of 4" exhaust tubing 4"-5" long, Spray paint for the tubing if not stainless.

Directions:
1. Remove entire stock air box assembly and loosen the clamp on the other end of the black hose connecting it to the engine.

2. Push the 4" exhaust tubing into the black hose and tighten up the stock hose clamp on that end only. The tubing needs to be stainless otherwise paint it inside and out to prevent it from rusting. I painted mine black and applied a THIN layer of grease on the inside of the stock hose and the new air filter so that the paint wouldn't stick to them when I change air filters.

3. Place the constant torque clamp over the air filter and push the air filter over the exhaust tubing - do not tighten the clamp yet. It is a good idea to mark the tubing at the minimum length that the filter needs to be pushed on, which is about 1"

4. Place the filter down into its possition as seen in the picture. You may have to rotate the black hose on the engine side some and adjust how far the the filter is pushed onto the tubing.

5. Tighten the clamp on the engine side of the black hose.

6. Once you are sure the tubing is going straight into the filter tighten the clamp. You may want to pull the air filter up out of possition and rest it on the battery but be careful of the positive terminal especiall if it is not covered. Put the filter back into its resting place and enjoy the new found turbo whistle (especially if you have a 3" downpipe installed)


Eric
96 F-350 CC Dually My TDG Gallery
B codes, head studs, Comp 910 valve springs, stock turbo w/ 1.00 turbine housing
6.0 IC, NAPA 6637 air filter, AeroTurbine 4040XL, ITP Overboost Annihilator,
Quadzilla Commander, electric fuel system w/ regulated return
coolant filter, 203* thermostat
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346.7HP, 852.1TQ 12/15/07 Greeley, CO w/ stage 1 injectors and Wildman tunes
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post #2 of 24 (permalink) Old 06-11-2007, 07:08 PM
 
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i called napa today and asked them about the 6637 filter, they quoted me $46.67. Any place i could get one cheaper, preferably offline? (no credit card to order stuff)
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post #3 of 24 (permalink) Old 06-11-2007, 11:05 PM Thread Starter
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The filters are a little pricey if you have to buy them at full price. Try going to other parts stores or filter dealers. The Wix number is 46637. Other places should be able to cross it over. fleetfilter.com has them for 24.87 + shipping. LINK

Eric
96 F-350 CC Dually My TDG Gallery
B codes, head studs, Comp 910 valve springs, stock turbo w/ 1.00 turbine housing
6.0 IC, NAPA 6637 air filter, AeroTurbine 4040XL, ITP Overboost Annihilator,
Quadzilla Commander, electric fuel system w/ regulated return
coolant filter, 203* thermostat
Dually Club Member #53

346.7HP, 852.1TQ 12/15/07 Greeley, CO w/ stage 1 injectors and Wildman tunes
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post #4 of 24 (permalink) Old 06-12-2007, 03:59 AM
 
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thanks racehauler, good write up too. The wix website told me a few places in my zipcode i could try.
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post #5 of 24 (permalink) Old 06-18-2007, 07:57 AM
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just making sure that will work on a 1996 7.3 and instead of exhast will PVC pipe work?

MN national gaurd member back in kawait and iraq playin army again...
1996 F250 7.3 4x4 DIY intake and 4in straight piped
1975 F250 460 2X4
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post #6 of 24 (permalink) Old 06-18-2007, 08:18 AM
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is the tubing used just straight tube or with some curves, and what was the approx length
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post #7 of 24 (permalink) Old 06-18-2007, 07:58 PM Thread Starter
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4 to 5 inches of 4" outside diameter straight tubing (anyting will work). You can see it in the pic. It is the shiny black piece between the clamp for the filter and the stock clamp for the intake hose.

Eric
96 F-350 CC Dually My TDG Gallery
B codes, head studs, Comp 910 valve springs, stock turbo w/ 1.00 turbine housing
6.0 IC, NAPA 6637 air filter, AeroTurbine 4040XL, ITP Overboost Annihilator,
Quadzilla Commander, electric fuel system w/ regulated return
coolant filter, 203* thermostat
Dually Club Member #53

346.7HP, 852.1TQ 12/15/07 Greeley, CO w/ stage 1 injectors and Wildman tunes
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post #8 of 24 (permalink) Old 06-18-2007, 08:03 PM
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were can ya get some or that pipe because i have only one exhast shop in my area and do you know if k&N make a filter that will fit it? thanks alot...

MN national gaurd member back in kawait and iraq playin army again...
1996 F250 7.3 4x4 DIY intake and 4in straight piped
1975 F250 460 2X4
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post #9 of 24 (permalink) Old 06-18-2007, 11:16 PM Thread Starter
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My local NAPA had some 4" exhaust tubing. Try the parts stores around you and you should find some. If you don't have any luck send me a PM, I have some left over from my exhaust system.

I know K&N makes a filter that is 4" that will fit in there but I'm not sure what the part number is. Here's a LINK to a filter that Dfuser sells that will fit. But I like the paper filters best myself.

Eric
96 F-350 CC Dually My TDG Gallery
B codes, head studs, Comp 910 valve springs, stock turbo w/ 1.00 turbine housing
6.0 IC, NAPA 6637 air filter, AeroTurbine 4040XL, ITP Overboost Annihilator,
Quadzilla Commander, electric fuel system w/ regulated return
coolant filter, 203* thermostat
Dually Club Member #53

346.7HP, 852.1TQ 12/15/07 Greeley, CO w/ stage 1 injectors and Wildman tunes
racehauler is offline  
post #10 of 24 (permalink) Old 06-19-2007, 01:42 PM
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o thanks alot ill let ya know when i get home...

MN national gaurd member back in kawait and iraq playin army again...
1996 F250 7.3 4x4 DIY intake and 4in straight piped
1975 F250 460 2X4
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