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Almost correct on all the steps to take.
On a 2003, the connection on the valve cover will be almost completely closed over by design, except for a small hole. In order to get the baffle out, you will need to enlarge that hole. The easiest way to do that is to simply pull the whole sleeve out of the valve cover. Once out, remove the plastic baffle and then open up the sleeve in whatever way you choose. On the earlier trucks the sleeve is just a straight tube.
The sleeve will gently hammer back into the valve cover. You do not reinsert the baffle.
Some people might be calling the baffle a nipple, because there is a small protrusion on the end of the baffle piece. When the baffle is in place on the earlier trucks, it looks like the sleeve is closed over with a small nipple on the top of it.
Thanks - I think I understand this a bit better now. The baffle is what some are calling the oil separator (the plastic spiral that’s inside of the metal sleeve on the passenger valve cover).
I was unsure of how much to enlarge the hole in the sleeve - 5/16? 3/8?
This Best4x4 mod is top notch. Everyone should do it. Easy.
...how, from the factory, was overpressured air/oil/fuel under the valve cover ever getting past that 2000-2002 oil "separator" in the first place without this mod?!
okay I drilled out the plastic insert from the metal sleeve.... now I have to enlarge the small hole on top of the sleeve then reinstall it back in place with out any type of plastic insert (oil separator) correct?
Yep toss all the plastic inside that tube into the trash. Drill out the tube and re-install. Now with the FV308 at the intake you have a PCV valve that will NOT clog up like the OEM plastic baffle.
How important is drilling out the 1/8" hole to a larger diameter? I was able to drive the old baffle out with a small pick and then reinstalled the metal tube in the valve cover as is.
