Windstar Intake Clearance - Hitting Hood

[CharlesHS]

Several years ago I was having an engine rough idle that I trying to troubleshoot. I replaced spark plugs and cleaned the TB IAC. While cleaning the TB when the spray approached the throttle plate shaft; the idle changed.
Over the years the TB casting around the shaft had worn causing air to be drawn it around the shaft.
Since there are no new replacement OEM throttle bodies available; I purchased a BBK 62mm; the factory is 56mm.
I reset the ECU and started the Jeep and drove around for a while. While I can’t specifically say there was an increase in HP; there was definitely an increase in TQ in the street driven RPM range.
You ask how I know this…
There is a long tall bridge crossing Blount Island Terminal on the way the Jacksonville airport. In the past the Jeep could barely maintain 55mph with the A/C on without downshifting. After the installation of the BBK throttle body; the Jeep could maintain almost 70 mph with the A/C on. ‘
How much that increase translates to; I am not sure, but it was quite noticeable.
I have looked at the fuel trim before and after; there was definitely a noticeable adjustment.
I am going to test what was posted earlier about removing and increasing the size of the factory air box intake horn.

 

[B1Toad]

Several years ago I was having an engine rough idle that I trying to troubleshoot. I replaced spark plugs and cleaned the TB IAC. While cleaning the TB when the spray approached the throttle plate shaft; the idle changed.
Over the years the TB casting around the shaft had worn causing air to be drawn it around the shaft.
Since there are no new replacement OEM throttle bodies available; I purchased a BBK 62mm; the factory is 56mm.
I reset the ECU and started the Jeep and drove around for a while. While I can’t specifically say there was an increase in HP; there was definitely an increase in TQ in the street driven RPM range.
You ask how I know this…
There is a long tall bridge crossing Blount Island Terminal on the way the Jacksonville airport. In the past the Jeep could barely maintain 55mph with the A/C on without downshifting. After the installation of the BBK throttle body; the Jeep could maintain almost 70 mph with the A/C on. ‘
How much that increase translates to; I am not sure, but it was quite noticeable.
I have looked at the fuel trim before and after; there was definitely a noticeable adjustment.
I am going to test what was posted earlier about removing and increasing the size of the factory air box intake horn.

Does the stock intake tube fit the BBK 62mm? Why the ECM reset, just so it would start a re-learn right away with the A/F ratio change? I have the telltale rough idle and the whistle at cruising speed and I suspect it is the TB shaft bushings. I also have a hard time trying to hold a raised idle speed at say 1,200, not sure if a new throttle body would help on that issue. (I like to put my hand throttle at 1,200 on hot days of city driving to help keep the ECT down and the AC blowing colder at long red lights.)

 

[Wildman]

I have no idea why anyone would want to do that. My kid has a Thor intake in his XJ. It is noisy AF in the passenger compartment. I find it annoying as hell.

I don't have the filter in the cowl but from all the comments I'd expected mine to be louder.

 

[CharlesHS]

Does the stock intake tube fit the BBK 62mm? Why the ECM reset, just so it would start a re-learn right away with the A/F ratio change? I have the telltale rough idle and the whistle at cruising speed and I suspect it is the TB shaft bushings. I also have a hard time trying to hold a raised idle speed at say 1,200, not sure if a new throttle body would help on that issue. (I like to put my hand throttle at 1,200 on hot days of city driving to help keep the ECT down and the AC blowing colder at long red lights.)

YES…. The stock intake tube fits over the BBK 62mm throttlebody OD.
The factory intake hole matches almost perfectly to the increased size of the BBK throttlebody.
YES…. Resetting the ECU to relearn the fuel trim to air flow.
I believe some of the whistling can be attributed to the air horn for the air box.
You can test for leaks around the throttlebody shaft spray throttlebody cleaner or even water to temporarily seal the leak. Couldn’t hurt to test around the base of the throttlebody for leaks.

 

[ColoJeep]

I don't have the filter in the cowl but from all the comments I'd expected mine to be louder.

I have a Banks Ram Air setup , it's louder that stock , but it does give better acceleration . Besides I kinda like the intake moan of a injected Rambler 6 banger.

 

[B1Toad]

YES…. The stock intake tube fits over the BBK 62mm throttlebody OD.
The factory intake hole matches almost perfectly to the increased size of the BBK throttlebody.
YES…. Resetting the ECU to relearn the fuel trim to air flow.
I believe some of the whistling can be attributed to the air horn for the air box.
You can test for leaks around the throttlebody shaft spray throttlebody cleaner or even water to temporarily seal the leak. Couldn’t hurt to test around the base of the throttlebody for leaks.

Charles can you answer a question about the BBK? Say you want to hold the RPM at 1200 or so, is it easy to do? I noticed on mine it takes a bit of practice, it wants to jump from regular idle way up into the teens if I don't do it just right. I usually have to gently ease down to 1200 then hold my foot really still. It's almost impossible to do it with the hand throttle. I don't know if that's just because of the way the TB is designed or if it's something else. Mine is definitely leaking around the shaft and not only from the carb cleaner test but you can feel and hear the looseness with your hand wiggling it.

 

[CharlesHS]

Charles can you answer a question about the BBK? Say you want to hold the RPM at 1200 or so, is it easy to do? I noticed on mine it takes a bit of practice, it wants to jump from regular idle way up into the teens if I don't do it just right. I usually have to gently ease down to 1200 then hold my foot really still. It's almost impossible to do it with the hand throttle. I don't know if that's just because of the way the TB is designed or if it's something else. Mine is definitely leaking around the shaft and not only from the carb cleaner test but you can feel and hear the looseness with your hand wiggling it.

Before installing the BBK throttlebody; I disconnected power at the battery while installing the TB to reset the ECU.
Initial startup the RPMs were a little erratic until the fuel trim was achieved.
I test drove the Jeep for almost 45 mins thru different types of driving to further trim the fuel.
Since then the increase and decrease of RPMs are smooth transitioning thru the RPMs from idle.
Hope that answers your questions….