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FWIW: For those still considering AIS Ran the AIS about 10K with the common restrictor guage issues present...moderate restriction commonly present on guage. Upon recent installation of 4" turbo-back exhaust, the guage immediately pegged with moderate to heavy acceleration, tripping the idiot light on the dash. Several resets...same thing. The AIS simply wasn't providing enough airflow, required by the addition of the 4" exhaust. All other mods remained constant. (SCMT @ 60, etc) Went back to stock airbox and the guage never moves indicating ANY restriction under WOT... even under heavy towing conditions. I know this has been discussed in much greater detail before under AIS in "Larry's Little Secrets" (here), but since a few recent threads have members considering the AIS, I thought I'd possibly save them the $200 experiment/mistake I made...thinking better filtration with no performance drawbacks. Bottom line: AIS great for those in severe dusty conditions, looking for better filtration, with stock or limited mods...inadequate for those with/or looking for certain performance mods. Again, FWIW |
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Are you sure the intake of the AIS was not blocked at the intake end? The AIS is alittle longer than stock an you need to cut out the rubber air dam in front of it and or cut out the fiber glass section in front of the intake. I have a 2002 4x4 Excursion with a MagnaFlow exhaust and run the SCMT in the 80 HP mode towing a 6000 LB boat and have yet to move the restriction gauge on my AIS. Its an great filter and flows way better than stock. Sounds like there is a problem with your set up? Ken |
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I second what ken527 had to say. I put an AIS air filter system on my truck and the intake tube was close enough to the flexible air diverter between the radiator and the grill that it was sucking it up against the air intake and blocking the flow. It was pegging my flow restriction gauge until I could figure it out. I cut the flap away and it's working great. The AIS flows much more than the stock intake system. Todd. |
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I have yet to have a problem with my AIS. I gross near 17k when towing and have yet to have an issue. I now change my air filter annually rather than every oil change. |
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I have to agree with the others whom have posted. I run the AIS with a 3.5" DP to a 4" exhaust. Last Dyno without the chip was 330 rwhp. I ran a 4 position chip from Jody Tipton to the Power fest rally in Indiana for a test. On the hills I ran the thing in the 80hp mode and on the flats I ran it in 120hp mode.  Never once was the filter minder pulled more than half way. Our GCW is about 17,000 lbs 7% grades in the 80 hp mode were a breeze and EGTs were never over 1250.
I have a huge Zoodad hole in my grill and have puddle jumped the truck in some massive standing water and never even got the filter wet! Dont want to sound like a smert arse but are ya sure you don't have a restriction? Also the filter minder that comes with the AIS is more sensitive than the stock one , it might be the other way around. Ya might want to talk to our resident Donaldson expert, I believe his name is Jordan. Trust me the stock filter setup on these truck absolutely stink compared to the flow and filtering capacity the AIS. If I can pull my 5ver in the 120hp mode and not have an EGT issue or filter minder issue that has to say something about the AIS! 
(added on edit) Max boost on last trip was 30PSI! See ya, Shane |
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Quote: Sorry to hear that you had trouble with the AIS intake.  I opted to go with the Volant intake,  big mistake, replaced it with AIS,  no problems at all, of course I have no major mods,  just a "work" PSD.  Bob |
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do this trick with the AIS, take your old sensor and put it on the harness , leaving the new sensor in the AIS, then just wire tie the sensor out of the way and no more tripped ais |
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Just put a new AIS element in. Pretty shocking how dirty the "outer" portion of the filter and box was. Pretty amazing how immaculate the "inner" part of the filter and box lid was. It was so new and shiny that it looked wet. The only thing I am doing different with my AIS is to use K&N Air Filter Sealing Grease liberally where the element seals to the box and lid. Scott |
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I am very happy with mine, and the 5 I put on the fleet at work. I had one that the rubber flap in the front kept getting in the way. On my truck with the upgraded turbo and I had to switch to my old filter minder. Now I can only pull it half way, which just means it's working. It will flow more air with less restriction than a tymar element. That was from the company who makes them both. I'd give it another shot before I sold it. |
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Hey joe, I wish you posted about your troubles first. I too had problems with the ais. I noticed a drop in fuel economy, couldnt figure it out. Well with help from these guys i realized that i had that dreaded rubber flap covering about 1/3 of the intake. I pushed the rubber flap back to where it should be and life is back to normal. If you still have the ais and are in the experimenting mood, give it another shot. From what i hear it flows enough for a chip. By the way, how do you like the exhaust, which brand? Also how many miles before i have to change my ais under normal driving conditions? Thanks |
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Quote:  I have never heard that before,not that i dont believe you,but where can i find this info?
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Look Here |
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Thanks Doc, very interesting report and i didnt doubt you for second 
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It shocked me as well when he posted it. I think what makes it hard to believe is the filter minder. The filter minder doesn't take anywhere near 25" to peg it. It is calibrated so that when a stock truck with the AIS has 25" at the turbo inlet, it trips. When you change the airflow of the engine it reads incorrectly. Thinking the filter is dirty when it's not. Anyone who is running more than stock boost needs to change the filter minder with the one out of the stock air box. |
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My early '99 with the upgraded air box didn't have anything connected to the filter minder. Is this something they did on the later trucks? My AIS instructions mentioned something about "if" you had a harness connected to the filter minder... mine didn't. Todd. |
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Okay,...As I sit here chewing on, gagging, and swallowing my perfectly baked, self-inflicted, "humble pie"...my current status regarding the AIS has again positioned itself at 180*. The rubber flap issue at the snorkel intake was never an issue (in my case) which led my instincts directly to the AIS filter element. Thanks to Dezl_Doc and your post above, and the link to Jflagstad's (Jordan of Donaldson) professional analogy and explanantion of the filter minder's chracteristics with various mods: Quote: Don't know how I missed this post back in early June...but I did, and apologize. I know many had suggested the same in various wording, but I just wasn't convinced that putting the stock filter minder on the AIS was the conclusive answer. I viewed it rather as a way to hide the symptoms of a greater problem...till now. So I reinstalled the AIS again this morning, swapped out the filter minders, and headed out WOT. No restriction registered...and now convinced...none present. MY PSD is now ready to head out with the 5'ver in a couple weeks, with the brothers, for THIS as their support and logistics vehicle across the country. Thanks to the invaluable and knowledeable folks here at TDS, the last two years of "getting my truck where I want it" has been nothing short of incredible. |
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That's why we are all on here, to help with problems and together figure this stuff out. I just pulled my fiver 6000 miles in one trip and can tell you the AIS worked perfectly. Glad you got it worked out, enjoy your trip, it's a very worthwhile cause. |
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So you are going to keep it. I was hoping to see it in the for sale section. 
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Quote: Quote:HERE AND Quote:HERE AND NOW..... Quote:HERE    Larry keeper of the "little secrets" CLICK HERE 
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I believe the AIS filter, like any other filter, has its flow limits. To me, seeing the filter-minder pegged simply means that it takes 25" of suction to pull the air through the filter. Seems like alot to me. You can switch to the stock filter minder which probably takes more than 25" to peg . Remember the posts about people finding nearly clogged filters, and writing that the filter minder had hardly tripped and therefore was a (edit) err, unreliable? But switching the minders just would solve the idiot light issue, and wouldn't make the filter flow better. Just kind of makes the issue go away. I see the filter minder as sort of a vacuum gage so it's difficult for me to accept that it's simply in the wrong place, or not "calibrated for the increased flow", huh? You mean if the flow increases and the restriction increases we need the minder calibrated how? Dale
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Quote: First remember this 25 is in "inches of H20" which equates to only around 2inHg. Based partly on what was posted about the "Ford specification" of 25inH20 at the outlet of the airbox I went and installed THESE and specifically plumbed in the air restriction gauge HERE and you can see where my "filter minder" is in relation to that vacuum line. Larry keeper of the "little secrets" CLICK HERE
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Well I agree with the other posters and am also very satisfied with the AIS. If I were in your shoes with no restriction with the OEM filter and significant restriction with the AIS, I would be looking for a leak in the OEM filter box. Rather have some restriction and good filtration to avoid a "dusted" engine. Apologies to others if this was suggested in posts above. I just skimmed most of the posts. |
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Larry, as always your work is impressive. I remember that it is 25" of water, back when the Donaldson engineer was posting. I was just trying to keep things simple, so I called it suction instead of pressure drop, etc. Although 2" of hg (vacuum) seems low in terms of vacuum, I'm envisioning it over the larger area of the turbo inlet. Dale |
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Well after reading all of this... I decided to do a little testing with my set up. I have a K&N FIPK set up and the Ford AIS. I noticed on my AIS the gauge would go about 1/2 up the scale. My truck pulls about 25 PSI of boost. I installed the K&N FIPK and used the gauge that came with the AIS and the gauge never moved. I modified the AIS by cutting off the first six inches of the inlet duct that is smaller then the rest of the duct. I re-installed the AIS and after two days of several wide open 25 PSI runs the gauge barley moved. Bottom line... I believe my AIS is a little more restrictive then my K&N FIPK but I believe the AIS will provide superior filtration and cooler air due to the fact it picks up air from the front of the truck. The only thing I was worried about when I cut the inlet duct was the temp of the air so I drilled a hole in the inlet duct on the AIS and installed my sensor that goes to my overhead temp reading in the inlet duct on my AIS. So far after two days of driving the inlet temp has been the same and the ambient temp. |
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Thanks Max for sharing the test. I'll have to consider trying that on my AIS. Problem for me is that my AIS quiets down my turbo enough that I get less noise from the passenger seat, if you know what I mean. Dale |
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Dale, Even with the inlet duct cut my AIS still keep everything nice a quiet.
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I have been concerned about that last(first?) piece of duct on the AIS since I put it in. Always seemed like the typical Ford way of doing things. Engineer something really great then mess it up. I was getting a small movement in my minder with the duct in place. I removed the duct and no more movement. I put a 7"dia alum piece of round duct in its place. Not air tight just to allow cool air flow from the front and a way out for the water. I am no engineer so I cant say how good this will be from that stand point. But it works for me. 
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You running a stock turbo Max? |
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Yep... still running the stock turbo and injectors. 160K miles and she still nice and tight. I have three chips. 70 HP TS, 100 HP WD, and 100 + BTS. The BTS is the best by far. Real good power, perfect trans shifting, no injector noise and 25 pounds of boost. The WD makes more boost, 30 plus but it smokes big time and the programing for the trans sucks. The BTS chip makes my trans shift spot on and is very quick and smooth. When the T/C hooks up you better be hanging on. Mad Max |
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Mad Max, Just curious where was the original air temp sensor location for the overhead ? And, what does it read when the truck is sitting in the sun or after stopping after a full temp drive?? Good idea, I think I'll try it with a separate sensor/guage.. Also as you're familiar with turbines what do you think of the airoturbine muffler for reducing Egt's and increasing mpg's,(sorry if it's off sub)??
Mike Edited by SCMike (08/20/04 01:18 AM) |
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The Air Temp Sensor is located on the Core Support behind the grill on the driver side. The harness for it is long enough to re-route it to the intake duct. My temps after the truck has set in the sun all day at work are the same as they were before I moved the sensor. They are about 5 degrees higher then ambient temp but they come down as soon as I get truck moving. My temps are 20 to 25 deg higher when I shut the truck down and let the heat from the engine soak in to the inlet duct. The temps come down as soon as I get the truck moving. I am not familiar with the airoturbine muffler. If you have some information on it I can have my engineers here at work look at it and see what they think. |
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MM, I think the Aeroturbine muffler has been discussed here but here's the WS http://www.aero-turbine.com/ ... I hope this off tangent isn't compromising this forum but it appeared to have reached a logical conclusion at the top of page 2... Thanks Mike |
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AIS OUT - Stock Back IN!
Re: AIS OUT - Stock Back IN!
