Engine/Transmission (1998.5 - 2002) 2nd Gen AFE stage 2 owners take caution

[Mcescolini]

After about 6 months I pulled it off and sold it to a kid that had just bought his first 95 Cummins, and then I went back to stock until I heard about Icebox mfg. Kinda cool that they are in my home town.

 

[BILLVO]

What problems did you see with yours? and why not let the company know instead of passing on a possible fire hazard?



This is the main reason for this thread is the potential hazard of fire and or engine damage it poses.

 

[AFarmer]

I see your point Bill - never had that happen before. The standard media oil style element IMHO has the ability to flow more.

 

[Mcescolini]

The same problem as you with the intake tube showing signs of heat distortion and also the filter was beginning to collapse. I bought mine of ebay and it was used so not much I could do. I never considered the possibility of a fire hazard until reading this post. As far as I know the kid I sold it to is still running it.

 

[BILLVO]

I too bought mine off of e-bay. I got lucky though by running into the afe rep at the dyno day at the NHRDA event in Billings last weekend. He got the ball rolling for me. But now that they know of the problem maybe others should all contact afe and keep the ball rolling so nobody burns a pickup to the ground.



They also contacted the company I purchased it from and they are the ones getting credit for sending me my replacement setup now. When I talked to the people I bought it from they too were concerned when they heard of the problem with the stage 2 tube.

 

[BDR]

Hey Billvo~

I looked at my tube, and mine too is fairly melted. Should I just call and tell them what is going on. Or do you have a number for the rep you talked to? PM me with the details if you wouldn't mind.

 

[BILLVO]

I will PM anyone who wants the reps Name and number.



BDR I sent you a PM.



Here is the e-mail link to AFE tech dept.



-- email address removed -- <tech@afefilters.com>



By the way do not confuse the indent on the bottom front of the tube assembly where it is made to clear the turbo oil feed line as a melted spot. Just a FYI.

 

[BDR]

Thank you, I appreciate it!

 

[DerekW]

its cool having someone pay for your stuff or give you free stuff no doubt. but why dont yal consider getting afe to read this thread and get them to consider a heat sheild on their intake??? that may be the solution to your problem while breathing nice and free for econ or HP. thermal barrier on the intake plumbing and theramal barrier on the turbine housing. that sounds like a winner to me.

 

[Extreme1]

I recommend a shield on the turbine housing. I got a stainless one from Larry B, Phone: 253-272-1444. He has them for 35's and 40's. Makes a noticable difference in radiant heat.

 

[BILLVO]

its cool having someone pay for your stuff or give you free stuff no doubt. but why dont yal consider getting afe to read this thread and get them to consider a heat sheild on their intake??? that may be the solution to your problem while breathing nice and free for econ or HP. thermal barrier on the intake plumbing and theramal barrier on the turbine housing. that sounds like a winner to me.

They did not give me free stuff just replaced with a trouble free system and they are well aware of the issue and have the same pics that are posted here. To do a heat shield on this intake would be tough as the pictures are deceiving. There is only about 1 inch between the turbo and tube. At that distance the radiant heat is there no matter what. If you put a turbo blanket on and or heat wrapped the tube they would be touching.

I recommend a shield on the turbine housing. I got a stainless one from Larry B, Phone: 253-272-1444. He has them for 35's and 40's. Makes a noticable difference in radiant heat.

I looked at this a while back but a lot of turbos are bigger than the stockers. Like the s300 series in dozens of configurations and housing sizes. And as stated above the tube is simply too close to the turbo for it to work. I can just barely get my fingers in between them.

 

[Forrest Nearing]

I never understood how that tube w/ all those bends could be all that better than a stocker with a nice gentle curve to it

 

[JJPage]

Can you replace it with a "COOL BLUE HOSE"?

They also make red and black now.

 

[BILLVO]

Can you replace it with a "COOL BLUE HOSE"?

They also make red and black now.

I believe that is just a 3rd gen thing but not sure.

 

[Bob4x4]

I just installed an AFE stage 2 dry s intake on my 02 and have noticed my egts had gone up about 100 degrees. I went to Billings for the NHRDA diesel drags. The first road trip since the install. When I got to the hotel I popped the hood and really looked at the intake and then reached under the air horn which is only about 1 inch directly above the turbine housing and the plastic horn was soft and mushy underneath. This really concerned me. Luckily at the Dyno event the local AFE rep was there and I showed him this and he realized the problem, took pics and sent them to headquarters.



If you all look at how the air horn runs directly above the turbo It heats the air horn thus heating the air inside causing higher egts thus defeating the purposes of a "COLD" air intake.



The real scarey thing is that it got the horn hot enough to make it soft and mushy. That was at normal driving egts 600-1000. If one were to be pulling hard at 1100+ temps for a distance I fear a total melt and possible fire and or engine damage from melted plastic being sucked into the turbo ect.



AFE will get on top of this I hope and make it right. I am writing this as a safety issue. I will keep you all posted on what they are doing to help fix the problem.



After he contacted the factory They claimed this kit has been out since 2000 and this is the first they had heard of a hot horn issue. The rep was then saying oh its the bigger turbo and maybe we need a disclaimer about running it on anything but stock units ect.



This will be the test for AFE customer service.

That is very interesting,I had the stage 2 on my 94 which can peg the pyro almost at will and never experienced that. It has been driven very hard in the sand dunes where there is very little air movement under the hood. On our last visit one of our participents had another 12 valve that we pushed so hard the firewall insulation was smoldering,no problem withthe intake.



Bob

 

[BILLVO]

Just an update. When I pulled the intake off when I got the new parts and had time. It had been about 2 weeks later and my tube had already started to distort from the heat. I didn't get pics of it though.



I got the stg 1 on and instantly noticed my idle egts dropped 100 and during cool down it cools down to 300 again with the stge 2 it wouldn't get lower than 400. cruising egt temps dropped about 100 degrees also. every thing else seems no different.

 

[PBliss]

After reading this I checked my tube, and it is not melted. I have had it for about a year. After I installed it I noticed a drop of about 100 deg egt while cruising, I can get egts 1300 deg pretty easily.

 

[PRout]

I ran one for a while and didnt have any of the mentioned problems either. I thought it was a well designed unit and it did what was claimed. The only thing I didnt care for was the intake noise. Did perform well though. .

 

[BILLVO]

Just thought I would bring this back ttt so new people can see it and let it not be a forgotten subject.

I have never done any follow up since to see if AFE actually did any changes to remedy this.

 

[Bob4x4]

Instead of bringing this back maybe you could have called AFE directly ??