6637 Intake Kit
Installation Instructions
Page 1 of 3
IMPORTANT: Before starting installation, please be sure that all items which were supplied with the kit are accounted for.
| 1 |
– 6637 Air Filter |
1 |
– 4” dia. powder coated metal tube |
| 1 |
– Riffraff Pre-Filter cover |
1 |
– large screw-type hose clamp |
| 2 |
– small zip-ties |
3 pages of installation instructions |
Installation (15-20 minutes):
1.Remove the Filter Minder and the Intake Air Sensor from the intake air box (Filter
Minder pulls out of the rubber mounting grommet; Intake air Sensor is removed by twisting it 90° and then pulling it straight out of its mounting hole). Push these aside for now.
2.Remove Air Intake Hose and Air Box lid – leave hose attached to lid. It is simpler at this point to leave the air intake tube attached to the air intake box lid.
NOTE: Some models have a fusebox beneath the air intake box, and for those situations, the stock box’s plastic mounting tabs will need to be trimmed. Some people trim these off regardless, but others leave them in place and nestle the new 6637element between them to allow for proper hood closure.
Leaving these protrusions in place helps prevent filter movement.
3.With the stock intake system removed,
you’ll probably see an oily residue inside the transition piece and hard tube leading to the turbo inlet. This would be a good time to remove and clean those parts to remove the dirty, oily residue, and you should consider doing the CCV Re-Route mod to prevent this residue from building up again (separate kit sold by Riffraff).
Toll Free Sales & Customer Service: (866) 446-3360
6637 Intake Kit
Installation Instructions
Page 2 of 3
4.Remove the soft rubber intake tube from the stock air box lid, and make sure to save the screw clamp.
5.Insert the black powder-coated 4” metal tube into the 6637 element as pictured to the right. There is a small ridge inside the filter’s “neck” which will not let the tube go too far inside the filter, but you will have to push hard to get the tube all the way in because it is a snug fit. The total insertion depth is approximately 2.5 inches.
NOTE: Uncoated metal tube is used in the pictures to make the process easier to see and follow.
6.Make sure the new screw clamp is all the way open and slip both it and your original clamp over the metal tube and down onto the filter neck, but do not tighten at this point. Then slide the rubber intake tube over the metal tube, leaving a 1” gap between the rubber tube and the filter neck, and slide the original clamp back into position on the intake tube.
7.Install the Riffraff filter cover and cinch the
drawstring around the filter neck to hold it securely on the filter.
TIP: The metal cage surrounding the filter’s paper pleats have sharp points and edges which can easily snag and potentially tear the fabric cover. This potential problem can be avoided by either of two installation techniques…
a)Roll the sides of the cover down like you might roll a sock down your leg before slipping it off your heel and foot, then place the end of the cover on the end of the filter element and unroll the sides until the filter is completely inside.
OR…
b)Get a grocery store plastic bag (Walmart, Home Depot, Lowes, etc.) and slit the bottom completely open. Insert the bag into the filter cover and open it up as if it were a liner inside the cover. Holding the top handles of the bag and the top edges of the cover, slide them together over the filter. Pull the bag handles to remove it from between the filter and cover.
Toll Free Sales & Customer Service: (866) 446-3360
6637 Intake Kit
Installation Instructions
Page 3 of 3
8.Both the Filter Minder and the Intake Air Sensor can be simply left lying on the fender liner where they will ride easily with no consequences. Alternatively, you can also zip-tie them to the brake master cylinder or the wiring harness on top of the fender liner as pictured to the right.
9.Re-connect the intake tube to the hard transition piece going to the turbo (where it was originally connected), and tighten all clamps to secure the parts together.
NOTE: If any of these parts do not stay together, your turbo will ingest dirty, unfiltered air which has been known to result in turbo and/or engine damage when not corrected very quickly.
Once you are finished, re-check all screws, bolts, and all clamps for tightness.
Credit for pictures and information to weekendwarriorsw32, jtharvey, Kwikkordead, F250_ and the whole FTE crew. Thanks!
Disclaimer of Warranties and Liabilities
Riffraff Diesel disclaims any implied warranties of merchantability and fitness for a particular purpose.
Riffraff Diesel also disclaims any liability or consequential damages including, but not limited to, repair labor, rental vehicles, hotel cost, or any other inconvenience costs.
This warranty is in lieu of all other warranties or guarantees, either expressed or implied, and shall not extend to any consumer or to any person other than the original purchaser.
Toll Free Sales & Customer Service: (866) 446-3360
