K+N 63-2612 Intake Structural Failure!

[livetoski78]

I opened up my K+N airbox today to clean and re-oil my filter. Imagine my surprise when this is what I found!

I can only describe it as a complete structural failure of the airbox. Almost every point that had a bolt or connector going through it has failed. For the life of me, I have no idea how this could have happened. Worse yet, I found a small plastic piece in the bottom of the airbox from one of the connection points. From the looks of it, there are many more pieces unaccounted for. I can only assume they were sucked up into the intake. God knows what damage it did to the turbo or the internals of the engine! I'm crafting an e-mail to K+N support now and will see what they have to say. Needless to say, I'm done with the airbox style cold air intake! More pictures below...

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[Dereku]

Unless you tightened the snot out of those connections, which I doubt. That is insane. Plastic would not damage the engine for the most part. Just get mushed up and shot out. I would be concerned about plugging the cat. Even then the temp should vaporize it.

 

[livetoski78]

I definitely didn’t overtighten them. To me, it looks like the vibration and movement of the engine stressed the plastic. There’s little to no give where the intake connects to the intake pipe when installed. Hence, anywhere something could flex, it did, with failure being the result.

 

[airline tech]

I definitely didn’t overtighten them. To me, it looks like the vibration and movement of the engine stressed the plastic. There’s little to no give where the intake connects to the intake pipe when installed. Hence, anywhere something could flex, it did, with failure being the result.

This is something that should be looked at deeper for possible bad motor mounts.
To see if more than normal engine movement is noted.
Holding foot on brake and in Rev and Drive loading the engine up.
I suspect you will find some abnormal movement for the damage shown

 

[livetoski78]

Bad engine mounts in 42k miles? The truck’s a road queen…I’ve never been offroad! Sounds like a trip to the dealer is in order.

 

[Frenchy]

Why a trip to the dealer? This isn't a OEM part so it won't be covered by the factory warranty.

 

[WOADKIL]

New motor mounts flex. Does the K&N filter allow for it w/o cracking?!?!

Are metal/non plastic parts unaccounted for?

 

[diesel924]

Sorry about your troubles. But just like the poor fella who installed an aftermarket turbo gizmo in another recent thread, your truck was a victim of an upgrade that wasn't needed. Hopefully no major damage was sustained from it.

 

[livetoski78]

Why a trip to the dealer? This isn't a OEM part so it won't be covered by the factory warranty.

To have the motor mounts checked.

 

[livetoski78]

New motor mounts flex. Does the K&N filter allow for it w/o cracking?!?!

Are metal/non plastic parts unaccounted for?

It doesn’t seem to. Plenty of missing plastic bits, but no metal from what I can see.

 

[Stevedbvik1]

Someone needs to take a bore scope and take a peek down the inlet to the turbo and see what your compressor wheel looks like .

 

[Rp930]

Just another reason to avoid K&N. Good luck.

 

[Glocker]

Can you post a photo of the airbox lid?

 

[livetoski78]

Can you post a photo of the airbox lid?

The lid was the only part that was fine. No damage there.

 

[harringtondav]

your truck was a victim of an upgrade that wasn't needed.

Agree. K&N cool air intakes had benefit years ago. Today our Rangers and other vehicles have 'cool' air intake filter boxes with large, effective air filters. I'd go back to the stock box if you still have it, unless you see a noticeable improvement in mileage and performance with the K&N.

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