Repair 2000-2004 Ford Focus Air Cleaner Box for under $25

Hello, I am a former farm machinery repairman and as some would say just a cheap skate who does not like spending my hard earned money if I can help it.

So when I went to change my air filter on my 2002 Ford Focus and could not get the screws out because the nuts were stripped out of the plastic housing.

The mechanic said it would cost over $300 for a new air box plus labor to install it.
I decided to repair it.

This pictures is of the box ready to go back into the car.

Step 1 Gather the needed tools and supplies.

You will need a screw driver to loosen the clamps.

A 13/64" drill bit and something to drive it with. (I used a drill press,) a hand drill would work.

A 1/4"-20 Tap and tap driver.

A vise grips, a 8mm wrench and something to mark the holes I used a 5/16" transfer punch,) any way to mark the center and make a punch mark.

A small hammer and a sharp chisel to remove the gussets or a dermal tool, (I used a Dewalt RotoZip tool with a 1/8" bit).

4 each 1/4"-20 stove bolts 1 1/4 or 1 1/2" long

A tube of RTV Silicone Make A Gasket, I used red Permatex Brand.

2 pieces of 1/2" square stock 9 1/2" long either steel or aluminum will work, I used 1/2" square steel key stock because I could buy 12" long pieces at Tractor Supply Co. on Memorial day when I decided to do the job. Aluminum would have been easier to work with.

Once you have the items you need, you are ready for step 2.

Comments

[DICK WEED]

Jiffy lube has been telling me for a while that mine on my 2003 focus are stripped and I just now looked to see what was going on. there was no "nut" like yours has, just the plastic tabs so if it ever had them they fell out. I was assuming there may have been some clip on nuts at one time that the techs at jiffy lube had just lost them till I saw your pics. Anyway I plan to try clip on nuts to fix mine. temporarly I just put some plane 6m nuts to keep it from sucking in dirt. my local auto parts store sells the nuts in the help section. here's an example

http://shop.advanceautoparts.com/webapp/wcs/stores/servlet/product_Radiator-Shroud-Clip-Nut-Kit-M6-1-0-Universal-Dorman---Help_89014959-P_N3102_A|GRP2037_____

if they fit the next issue will be to hope the crew at jiffy lube doesn't lose them

[vorgon4]

for anyone else looking to do this - consider an ebay search first, also check your scrapyard...

http://cgi.ebay.co.uk/Ford-Focus-1.6-Zetec-SE-Air-Filter-Housing---1998--2004_W0QQitemZ110665579817QQcmdZViewItem?rvr_id=225744325273&rvr_id=225744325273&cguid=5a87ca3212f0a47a2fb6fad6ffdf5aaf#ht_642wt_936

[GENO99100]

I HAVE A 2002 FORD FOCUS AND THE AIR FILTER BOX IS A SEALED UNIT. CAN I STILL CUT OR PRY IT OPEN AND PUT A NEW FILTER( WHICH I HAVE) IN IT? I DON'T WANT TP DESTROY IT. GENO

[GENO99100]

SORRY THE FOCUS IS A 2005. THANKS GENO

[Bosun Rick]

Why did you use carriage bolts? For the life of me, I can't see how you can tighten them (No machined heads, & shoulders that will eventually sink into the plastic of the box). I would have inverted the carriage bolts, and used nuts on top. Saving the time & effort of fabricating the bars; or you could use angle iron (as a stiffener) with standard nuts epoxied in place.

[jlsteiner]

Rick, I have no idea what you are talking about, where do you think I used carriage blots?? I used hex head bolts very easy to remove, but you can use what ever you want. As for the bars, I used what I had, you can do it your way, it is up to you.

[Bosun Rick]

My Bad, Mr. Steiner, My eyes saw "stove bolts", and my befuddled brain screamed "CARRIAGE BOLTS"! Senility is painless, unless you get caught! I apologize.

[jlsteiner]

No problem, I just did not understand your comment, Oh well you know what they say about what goes first? Now what was it? Have a good day!

[mrducky]

 Thanks for the instructions and suggestions.  I had exactly the same problem.  I used an X-acto knife to cut away the grommets to get vise grips on the nuts.  Then I cleaned the old bolts and nuts with WD-40.  I re-used the old nuts by putting them back in the plastic housing with JB Weld.

[cboy2us]

HeHe, I would have used a dremel on the old nuts, made some grip on them, and jb-welded them. not quite as pretty, but easier, and quicker.

[jlsteiner]

It might have worked but the first problem was getting the old rusted bolts out. That is why I had to remove the gusset so I could get a vise grips onto the nuts. This was a real easy fix, took less than an hour and it is definitely permanate. I could have wire tied it but I don't trust wire ties to keep it tight enough to keep dirt and dust out. My way is just a suggestion. I am sure there are many ways that haven't even been mentioned.

[cboy2us]

Very true, and for rusty bolts I recommend aerokroil, I use it on exhaust bolts and nuts, the stuff is kinda expensive, but well worth it, I have seen it loosen rust frozen bolts that I would have broken off by trying after 24hours of soaking in wd-40.

[jlsteiner]

For rusty bolts I recommend JB Blaster, has always worked well for me. Still can't get to the nuts without removing the gussets once the nuts spin in the plastic housing.

[jpitha]

I actually had this exact problem last month, and like carpespasm said I just zip-tied it in place. This is a much more elegant solution though!

[jlsteiner]

I would be afraid a zip tie brake or not be tight enough then there could be a leak between the air filter and the box cover letting in dirt that would go right into your intake and into the engine which would wear the piston rings and ruin you engine very quickly. This would not be good. But then perhaps I am just too cautious.

[jlsteiner]

The problem I see with zip ties is if one breaks or you do not get then tight enough you could loose the seal between the air filter and the cover which would let dirt get sucked into your engine and wear the piston rings causing your engine to start using oil. This would be bad. But then again perhaps I am just too cautious.

[geopan81]

jlsteiner

A late post, my daughter's Focus had the same issue & I had no clue how to proceed until I found this site with your neat tip. This was several months ago, I'm just writing to say thanks for the info & the saving of $$$$$. Also your pictures were a big help.

geopan81

[carpespasm]

A nice fix and you don't have to worry about the nuts on a new 300 dollar air box doing the same thing next time you need an air filter. Some folks would have simply zip tied it in place.

[alex-sharetskiy]

That's a nicely clean engine!