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The Kwik Filter open intake modification was named after
Kwikkordead who introduced the method of making a working filtration system for the 7.3 PSD using a NAPA 6637
filter element to the FTE forums. The DIY Tymar filter mod was around before Kwik introduced it but few members on FTE were aware of how
well it filtered and how opened up the intake on the 7.3L Ford Powerstroke Diesel.
When I initially did my Kwik mod, I left the filter restriction sensor module zipped tied to a section of wire harness next to the
old filter bracket. I never liked the idea of it just laying there and eventually capped the sensor end
with a plastic cap to keep the dust out. I wasn't satisfied with the installation until
SpringerPop showed us his way of installing the
FilterMinder in the end of the 6637 filter element and I did it this way until I installed my Ford AIS sytem.
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This page will take you through the steps of modifying the NAPA 6637 filter element to accept the original filter box
grommet and filter restriction sensor.
Got a question? Contact me on my DieselOrings.com webshop CONTACT PAGE
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Begin by setting the filter on a clean workbench and centerpunch the top of the 6637 filter where you will be installing the
filter restriction sensor module.
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Roll up a piece of cardboard that is exactly 12 inches long and place it inside the filter element to keep plastic shavings away
from the filter material as you cut the hole. Here I am using corrugated cardboard but any heavy paper like kraft paper will work as
well.
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Insert the cardboard so it is flush with the neck and square with the top of the filter.
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I have found that a Forstner bit - 5/8 inch will make the cleanest hole to insert the factory grommet into.
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Keep the drill motor vertical with the top of the filter and drill a 5/8 inch hole through the top.
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With a sharp razor, make a narrow bevel around the hole to assist in inserting the factory grommet. Be careful not to
enlarge the opening while doing this to assure a tight fit for the grommet.
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Tap on the sides of the filter element to knock any of the plastic shavings that may be clinging to the cardboard insert and allow
them to fall through the bottom. While holding the filter in a vertical position, pull the cardboard from the bottom opening of the 6637
filter.
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All of the plastic shavings that entered the filter should have been trapped by the roll of cardboard and cleanly exited through
the base.
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Look into the open end of the filter element and make sure there are no burrs around the hole you drilled or any small fragments
of plastic clinging to the filter media. Shake and tap the filter until they fall out if you find any.
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Insert the factory grommet into the 5/8 inch hole, it is tight so I spray a little silicone lubricant or WD-40 on the base to
help.
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When you have pushed the grommet in place, I have found that it tries to fold on the ridge on the inside. You may have to
reach in the filter and spread the bottom edge lip while twisting the grommet to make it lay flat.
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Once installed, your grommet should look like this.
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Rub a little WD-40 from your finger around the tip of the filter restriction sensor and insert it firmly into the grommet.
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Before reinstalling the filter on the truck, take a look down the intake tube towards the turbo. It should be clean, without signs
of dirt or dust clinging to the sides. If you have not done the CCV modification to your intake, you will
have a coating of oil covering the intake tube and you may see some puddles of oil on the turbo intake flange.
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Here is the filter with the restriction sensor installed on the end of the 6637 filter element. Lots of air for the 7.3 PSD!
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Back to guzzle's Powerstroke Modification Index |
