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

[BILLVO]

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.

 

[AFoulk]

I always wondered about the way they designed the stage 2 kit. Everyone else that makes one for the second gens. routes them the same way as the factory.

 

[BILLVO]

Here are a couple of pics of it. You can see the discoloration on the bottom of the tube from the heat.

 

[BDR]

I would have never thought that to be an issue. I will have to keep an eye on mine. Thanks for the heads up and keep us posted.

 

[SAndreasen]

realy glad i dont have the stage 2 dry intake . as far as afe customer service it i sucks in my dealing with them my filter started to come apart in the inside of the cone and they wouldnt warranty it . it definatley lowers my egts a lot i cant pull running wide open without it my egts get to hot .

 

[jwilliams3]

I would remove that intake asap...



I would also suggest that AFE make it right by sending you out an AFE Magnum "race" version (same filter) of the stage 1 intake and compensate you the difference in price.

 

[BILLVO]

I would remove that intake asap...



I would also suggest that AFE make it right by sending you out an AFE Magnum "race" version (same filter) of the stage 1 intake and compensate you the difference in price.

There are only 2 intake types for 2nd gen stage 1 and stage 2. They run several different filters for each stage though giving them all different part numbers for the kits depending on which filter you want. The stage 1 has a 4 inch throat and the stage 2 has a 6 inch throat.



I guess the 4 inch will have to do if they will do a swap.



I am waiting for the rep to call me back yet tonight.

 

[AFoulk]

let us know how ya make out. I was looking at getting a stage 2 eventually, but not if I'm gonna have to worry about the thing melting

 

[BILLVO]

I just talked to the rep and told him I want to get rid of the stage 2 due to faulty design and trade for a stage 1 pro dry s and a prefilter and a torque tube. He will let me know tomorrow if they go for it. All together it would be about same value as stage 2.

 

[jwilliams3]

There are only 2 intake types for 2nd gen stage 1 and stage 2. They run several different filters for each stage though giving them all different part numbers for the kits depending on which filter you want. The stage 1 has a 4 inch throat and the stage 2 has a 6 inch throat.



I guess the 4 inch will have to do if they will do a swap.



I am waiting for the rep to call me back yet tonight.

Stage 1 has a 4. 5" throat.

Stage 1 "Race" has a 6" throat and uses the same filter as the stage 2.

Stage 2 has the 6" throat.



I guess someone there might not know about the race unit since it wasnt really known well but it was a predecessor of the stage 2.

 

[BILLVO]

Stage 1 has a 4. 5" throat.

Stage 1 "Race" has a 6" throat and uses the same filter as the stage 2.

Stage 2 has the 6" throat.



I guess someone there might not know about the race unit since it wasnt really known well but it was a predecessor of the stage 2.

Thanks for the info. I just left the rep a message to check if the stage 1 race is still available.

 

[AFoulk]

does anyone have pics of the "race" intake? I checked afe's site, but they didn't have any pics of it.

 

[jwilliams3]

54-10771 Thats the part number for the race unit.

Looks the same as the stage 1 except has flange for larger stage 2 filter.

 

[BILLVO]

54-10771 Thats the part number for the race unit.

Looks the same as the stage 1 except has flange for larger stage 2 filter.

I checked with them and that kit and part number are no longer offered. It is replaced with a stage 1 kit of your choice with the torque tube which is what I am trading for along with a prefilter. It is 4. 5 inch flange. They are sending the kit out asap so they can get my kit back to analize the tube.

 

[jwilliams3]

The stage 1 will suit you just fine they are good up into the 600+hp area.

 

[MRose]

I checked mine tonight too, it obviously gotten too hot and is now melted. I have ihad t over a year now, will they warrenty?

 

[AFarmer]

Standard media style filters work best. Your problem lies in the material of the filter. I personally have several customers locally that are big fuel guys running those intakes with no problems. Make them give you another filter first and see if that cures your problem.

 

[BILLVO]

Standard media style filters work best. Your problem lies in the material of the filter. I personally have several customers locally that are big fuel guys running those intakes with no problems. Make them give you another filter first and see if that cures your problem.

MRose I would contact the company you bought it from and then have them contact afe. When they found out about mine they agreed to what ever I wanted right away with no problem. So they are sending me a stage 1 dry and a torque tube and a pre filter in trade for my stage 2 kit.





Gus this thread has nothing to do with the filter.

But which media are you saying is standard and is better, the oiled or the dry?

Look at the pics. the intake tube from the filter box to the turbo runs directly over the top of the turbo. It is picking up the radiant heat from the turbo being about 1. 5 inches below it and causing to get hot and melt or get soft in my case I saw the problem soon enough. Every other intake system runs the tube in a similar location as the stock one, at an angle to the side and away from the turbo not directly above it.

 

[Mcescolini]

I had the same problems, and now I have an Icebox. Check it out Icebox Manufacturing.

 

[BILLVO]

I had the same problems, and now I have an Icebox. Check it out Icebox Manufacturing.

How did afe handle it? Did you have a melted stage 2 tube? What did you do with your old system?