OEM airbox design bothers me

Has anyone noticed how the air filter is visible at the back edge of the airbox? With an OEM black air filter, it’s not noticeable, but it is with a Wix orange filter. This lead me to check how tight that edge of the airbox is, and you can tell that a laminated card fits between one “clip/slot thing” and the back one seems tighter. Rough edges on the clips also appear to gouge the plastic slots, but I’m not sure if this is even a factor in how tight it seals up. Either way, I can’t say I’m real confident in this design.

 

Now I wanna check mine . The OEM Denso filter has a foam gasket and it has a fair amount of squish to it.

I wonder if this was ever an issue on the 2nd gen boxes that used the Donaldson depth-loading type OEM filters (with the rounded corners) before Toyota switched to the rectangular Fram-looking type in '14 V8 models.

 

To make it even worse, there is a bump on one of the clips that was a defect in the mold, and since noticing it, I am more careful about the putting the lid back on the base to keep from gouging the plastic even more.

 

With the Denso 17801-0P100 filter it's quite tight on all corners. I can't get anything under those rear lock tabs.

Check the thickness of the Wix filter gasket. The OEM filter is about .450"

Edit: That gap where you can see the edge of the filter looks just like mine, no doubt designed for plenty of clearance so manufacturing variance wouldn't risk impinging on fit and function

 

I wouldnt worry on this. I noticed this after putting in my TRD Pro CAI kit. I noticed this right away. I kinda look at it in a positive way now. When ever I take my truck in for maintenance, I want to make sure they dont throw my TRD Pro air filter. It's a quick look and I can see it without opening the box. It has been over a year now and no warning lights or any notice of loss in power.

 

I will probably get a Denso and give it a try. I’ve always been happy with Wix, but if thickness is an issue then hopefully I haven’t sucked too much crap into the intake in the last 16,000 miles.

 

Considering that laminated card thing you were able to fit under there was probably only about .020 or so, that's not a lot of wiggle room for the filter's tolerances. Good reason to stick with the Denso I suppose. I was thinking of trying the Wix in the future too because they're really good filters. This box should probably have been designed with more snap down clips.

 

Another option that might work in the short term is to put it together with a shim above each tab. Perhaps cut a piece of an old bike tire inner tube and fold it once for thickness. Or maybe a piece of gorilla tape and just keep folding it over on itself 4-5 times in a way none of the adhesive is exposed.

Do you see dirt in there?

Also for that laminate you tested clearance with, did it fit in there loosely or did it take some pressure on the lid? If I push down with maybe 30# of force on the top of the lid I can get a little clearance to show. It looks like it will always seem looser on the engine end because the lid/box has limit stops at the clips so they can only clamp down the gasket so much. If the box is properly made the tapered tab should have the engine end of the lid at the same level of gasket compression as the clip end. Since there's no stops on the engine end you can squish it however much you have muscles for.

 

I didn’t have to overly force the card, but I noticed with a hot engine compartment, the card won’t fit. If you look on the underside of the top of the airbox, you’ll see a second layer of protection that appears to prevent anything from passing over the top of the filter. The inside of that plastic rim appeared to be perfectly clean and dirt & dust free with the exception of a handful of small specs that resembled dots of lint that were visible under a flashlight, but there definitely was not a layer of dirt or dust like everywhere else under the hood. Looked good for 3 years and 46,000 miles.

 

I’ve been using the K&N cleanable filter and it’s exactly like the TRD one. I haven’t noticed anything like your pictures show on my 16 limited. But it’s great you posted up. If your having this, most likely others are too.

 

Well, the foam edge on the Denso must be very very slightly thicker. The box felt noticeably tighter and I had a much more difficult time sliding the laminate card in the tabs.

 

Thanks for the confirmation. I'll be sure to keep the denso filters in there too.

 

I have to wonder if this was a cost cutting measure. The 2nd gen model I just looked at had a clip on every corner so it clamped super solid and the lid had much more volume like the current-gen TRD lid. Plus it had the Donaldson filter I wish I could get.

I need to see if a retrofit is possible

 

Cost cutting measure? You mean like deleting driver's grab handle, lights in door bottoms, dual hvac controls, lighted ignition ring, amber flashers/signals, dual glove boxes, sliding console and transmission cooler? Absolutely! All these features were included in my 2010 SR5.

 

What is everyone's thought's on a potential issue from having this gap? Is this causing a 3mpg loss or significant/noticeable power decrease?

 

Maybe it could suck in some dirt? Whistle? I sprung for the TRD air box to get more cold air.