Installing a 1996 seven. 3 cold air intake is probably the particular first thing any kind of OBS (Old Body Style) Ford proprietor should do when they want to wake up up that legendary Powerstroke engine. In the event that you're still running the factory airbox on your '96, you're basically asking one of the best diesel motors available to inhale and exhale through a cocktail hay. It's restrictive, this gets clogged easily, and honestly, it's just outdated technology for a truck that's built to work simply because hard as they perform.
The 1996 model year is a bit of a sweet place for Ford enthusiasts. It's got that classic square-body look, but it's modern enough to deal with some serious bolt on performance. When you swap out that stock plastic housing for a high-flow intake, you aren't just looking intended for a fancy pipe under the engine; you're looking intended for better throttle response, lower exhaust fuel temperatures (EGTs), and that sweet turbocharged whistle that each seven. 3 owner craves.
Why the Stock Airbox Just Doesn't Cut This
In case you pop the hood of a bone-stock 1996 F-250 or F-350, you'll see this flat, pancake-style filtration system housing. Back in the mid-90s, Ford producer was more concerned about keeping issues quiet than they were about maximizing airflow. The problem is that diesel engines are essentially large air pumps. The more air you will get into the cylinders, the more efficiently a person can burn gas.
The factory setup upon the 1996 seven. 3 is notorious for "filter minder" issues, where the vacuum gets so high from constraint it pulls the particular little sensor into the red. A whole lot worse, the stock boxes are known to leak. If dust gets past that seal, it will go straight into your turbo compressor wheel, "dusting" turbo charged and top to an extremely costly repair bill. Switching to a dedicated 1996 7. 3 cold air intake eliminates that will risk by offering a much more secure close off and vastly more surface area for filtration.
The DIY Route: The Popular 6637 Filter
You can't speak about a 1996 seven. 3 cold air intake without mentioning the "6637 mod. " If you hold out on any kind of diesel forums, you've seen this pointed out a thousand occasions. It's the greatest budget-friendly way to get more air into your rig. Basically, you buy a massive Donalson or Napa 6637 industrial paper filtration system, a short item of 4-inch exhaust system pipe or even a PVC elbow, and also a few of hose clamps.
It's not the prettiest part of the world—it basically looks like a giant white drum sitting within your engine bay—but man, will it work. This flows significantly better than stock. The particular only downside is definitely that it's a good open-element filter, therefore it's going in order to suck in a few warm under-hood air. However, on a 7. 3, the particular sheer volume of air it offers usually outweighs the slight increase in intake temperature. Plus, the sound is incredible. You'll hear that turbo spooling up from the stop away.
Moving Up to Aftermarket Intake Kits
If you need something a little more "finished" than a filter on a stick, there are some great designed kits out generally there. Brands like S& B, Banks, plus aFe Power have been making intakes for these vehicles for decades.
S& B Content
S& M is a huge favorite intended for the 1996 seven. 3. Their kits usually have a fully enclosed clear-lid airbox. This is great because it defends the filter from engine heat and splashing water, but you can nevertheless see when the particular filter is dirty without taking the whole thing aside. It looks expert, fits like a glove, and these people offer both dry and oiled filtration system options based on where you drive.
Banks Ram-Air
Banks is the particular "old guard" associated with the diesel world. Their Ram-Air system for the '96 Powerstroke is made to force as much cool air as possible in to the engine. They put a great deal of work into the aerodynamics of the intake tube to reduce turbulence. If you're towing heavy trailers over mountain goes by, keeping those EGTs down is your own main concern, and Banking institutions is ideal for that.
What Performance Increases In the event you Actually Expect?
Let's end up being real for the second: bolting upon a 1996 7. a few cold air intake isn't going to all of a sudden turn your pickup truck into a 10-second dragster. Anybody tells you that an intake alone adds 50 horsepower, they're most likely trying to sell you something.
Whatever you will notice will be a much snappier throttle. When a person hit the pedal to merge onto the highway, the particular truck won't feel like it's hesitating quite as very much. You'll also notice a drop in EGTs by about 50 to one hundred degrees in some instances. That will might not sound like much, but whenever you're pulling a 10, 000-pound movie trailer up a 6% grade, that additional breathing room retains your engine safe and sound.
And then there's requirements. The 7. 3 Powerstroke has the very distinct, large idle, but the particular turbo is frequently muffled by the share intake. A cold air intake enables that Garrett turbocharged sing. It makes the driving experience much more fun, actually if you're simply running errands.
Installation: A Weekend Morning Project
One of the best reasons for working on a 1996 Ford is that will there's actually area within the engine bay. Unlike modern trucks to have to remove the cab just to modify a lightbulb, the 7. 3 is pretty accessible.
Installing the 1996 7. 3 cold air intake typically takes about 30 to 45 minutes with basic hand tools. You'll mostly just require a flathead screwdriver or perhaps a nut motorist for the hose clamps and maybe a 10mm socket for the bolts holding the stock airbox in place.
- Remove the particular old stuff: Unclip the particular factory airbox cover, remove the filtration system, and unscrew the housing from the fender well.
- Disconnect receptors: Become careful with the Intake Air Temperatures (IAT) sensor. You'll have to move this to your fresh intake tube.
- Mock up the new kit: Slip the new intake tube into the particular turbo inlet shoe. Don't tighten anything yet; you would like several wiggle room to get everything lined up.
- Secure the box/filter: If a person have a kit with a box, bolt that straight down first, then attach the filter.
- Tighten and test: Once everything looks straight, tighten the clamps down (don't over-tighten and crush your invisalign aligner! ) and choose a test drive.
Maintenance: Oiled vs. Dry Filter systems
When you purchase your 1996 7. a few cold air intake , you'll normally have a choice among a "washable oiled filter" and the "dry disposable/washable filtration system. "
Oiled filters (like the classic reddish colored ones) are great mainly because they last permanently. You just clean them, let them dry, apply the little oil, and you're back within business. The drawback is that in case you over-oil them, that will oil can get sucked onto your own sensors and trigger issues.
Dry filters are much more well-known these days. They're simpler to maintain—you usually just blow all of them out with compacted air or change them after twenty, 000 miles. In case you live in an extremely dusty environment or do a lot of generating on gravel streets, a dry filter is often the particular safer bet intended for a 7. several.
Final Thoughts on the Upgrade
Is a 1996 seven. 3 cold air intake worth the cash? Absolutely. Whether you go with the $80 DIY 6637 setup or the $350 S& B enclosed system, you're doing your engine a massive favor. It's an simple, rewarding project that will protects your turbocharged, improves efficiency, plus makes your pickup truck sound like the beast it has been meant to be.
The 7. 3 Powerstroke is a legend for the reason—it's built to last. Giving it a better way in order to breathe is simply part of making sure it stays on the road regarding another 300, 500 miles. Plus, every single time you hear that turbo spool up while you're pulling a load, you'll are aware of it was cash well spent. Keep that OBS Ford producer breathing easy, plus it'll take care of you to get a long, long time.