Engine top crossmember issue?

Deleted per request · Mar 10, 2024

I have done a Explorer intake swap and now the engine top crossmember is hitting the top intake in the drivers back corner. What have others done to get the clearance for it?

Daryl · Mar 10, 2024

Are you referring to just under the furthest back of those 3 marks/scratches? It hitting the intake at that corner? If it’s “just barely” catching the corner, I’m wondering:
1. If there’s enough meat on that corner to file it down if the intake is metal; or
2. If the intake is plastic, again, either file/sand it down to clearance the corner or if you have to remove more and it makes a hole, maybe plasti-weld a straight piece to cover it.

Just some food for thought. I definitely wouldn’t “kink” the shock tower support. Might weaken/deminish its strength and effectiveness.

Deleted per request · Mar 10, 2024

Thanks Daryl but the intake is cast aluminum and it needs to go over the width of the tube. So the tube either needs to be cut and moved or splice a piece along side and then cut out the tube, neither will look great. The tube on the drivers side does have a bit of an offset but looks like it might have been installed rolled but not sure it would be enough if straightened. Not everyone run with these so is it necessary to install??? How much twist would this stop not sure.

Daryl · Mar 10, 2024

Can a new piece be routed and bent to circumvent that corner entirely? Kind of like bending metal brake lines?

Daryl · Mar 10, 2024

maybe try a Sesrch in this forum using keywords like Explorer intake, fitment, issues… etc etc
Sorry I wasn’t any help but hopefully someone who can relate to this problem will see the thread and chime in. Good luck and welcome again to The Herd!