I have had nothing but noise problems from the 3" AFI CAI since installing it.
1st I had to bend the support bracket so the filter would not rub on the underside of the hood. 2nd there is still way too much vibration from low-mid RPM range. 3rd seemed like I was getting great gas mileage at the begining, now it was down to 15.3 MPG . 4th I reset the battery thinking the computer had to re-learn the new intake, but still ran the same. Makes the truck sound like it's running rough POS. It's not the air coming into the intake when I punch the gas that bothers me, but the vibrations that drive me nuts. I called Troyer to see if someone could help me resolve these issues, but they said they never had any complaints about this intake. That's funny they should read some of the posts on hear. I called AFI tech support they asked if I had talked to Troyer, left a meassage and they never returned my call. I was going to wait till I got my custom Troyer tunes, but it has been over 6 weeks now and I could not take the intake noise anymore. So I removed it and installed the factory air intake, WOW the gas mileage went up about 2MPG and did not loss any power. Called Troyer too see if they would return the intake less then 2-moths old, but they would not. So it's sitting in the box it came in on my garage floor. Might be used as a giant paper weight someday. The Magnaflow SISO exhuast I really like, no problems there. Hopefully I will not regret the custom tunes once I install them, hopefully it will run ok with stock intake. I'm not trying to bash T.P. I'm just frusrated with the AFI CAI.

 

you sure they sent you the right model for your truck?

 

I have a vibration noise when I first accelerate, but it goes away after a few seconds. I can't figure out what the noise is, but it isn't to the point that you describe or to the point that is really bothers. The only thing that bothers me about it is I can't figure out what is causing it.

Is TP changing your tunes to account for the stock intake now?

 

Where do you live in the Valley....maybe you could look at mine and see if there is something different with yours. I have had ZERO problem with mine!

 

Is your MAF sensor in the same position on the AF1 as it was with the stock intake? I've seen several posts here with the same problems you're having and some of them had mounted the MAF at like 90 degrees from where it should be. It has to be the same orientation as it was with the stock. Most of their problems were fixed by putting it in the correct position.

I had a vibration issue as well when I first installed mine. Turned out to be that the two metal studs on the heat shield weren't seated COMPLETELY through the rubber grommets. A touch of silicon grease and they popped right through, a little adjustment to make sure the tube wasn't touching the heat shield and no more vibration.

Hope any of that helps!

 

Hopefully the tunes will be fine since I had the 3" AFI, which they say is ok to go back to the stock intake with custom tunes. Guess I'll find out for sure whenever I get the tunes.

 

Yes I installed the MAF sensor correctly with the arrow pointed going with air flow toward the cab. My heat shield was vibrating also under a load going up hill @3-4k, but all the hardware was tight and double checked. Some people can deal with vibrations and I chose not to. Plus it seemed to make the truck run boggy overtime at the low-mid RPM range also. I think I read a post about someone else having issues with this intake and that especially when the engine was heated up. I could tell there was a difference the way the engine ran from when the truck was cold and hot. Those AFI installation instructions are great aren't they? NOT. Thanks for replying.

 

According to Troyer it was the 3" AFI for 2004 5.4 liter. I thought they sent me the 3.5" originally. Because when I measured the outside diameter of the intake tube it measured 3.5". So I called them to make sure I had the 3" and they informed me that the dimensions are measured on the inside part of the tube and that the P/N # I had was the correct CAI.

 

I live in South Chandler. I think it's just the intake design, some people can live with the vibrations. Seemed to make my truck run boggy also. Filter seemed so flimsey when mounted to the intake tube, like it was too big. They should have made some brackets to hold the filter steady during load. Seems to bounce around like a basketball with flick of a finger.

 

"the arrow pointing in the right direction" was not what I was referring to as far as orientation. It's impossible make "the arrow" point in the wrong direction.

I guess I wasn't clear enough for you. Too bad you want to trash it, it's a fine intake when properly installed. Incorrect orientation causes the problems you've had.

 

Well I have the 3" AF1 installed also. I like the way the truck runs with it. But the annoying noise I experience is a high pitched whistle at low RPM. It almost sounds like a supercharger. Well I called Troyer also, they sent me to AF1 Tech. AF1 Tech said it happens sometimes and it is what it is. So far it is still installed on the truck (my wife hates it).
My Troyer tunes will be installed today. See what happens. I do find it odd that the 3"AF1 makes no difference with the tune. I would have thought a performance product would affect a custom computer tune. But on the other hand I don't understand anything about computer tuning.

Oh and I haven't experienced any vibrations.