When I did this mod last fall it took some patience to get the baffle out of the tube, as Best4x4 acknowledges. I sprayed it with carb cleaner or PB Blaster and let it soak for a while.

Then I grabbed and wiggled it with needle-nose pliers, sprayed some more, wiggled it some more, sprayed some more, wiggled it some more, sprayed some more, wiggled it some more and it eventually came out. But not without the top part of it first breaking off.

In the case of my truck the baffle wasn't cruddy enough to block air flow, just cruddy enough to need some coaxing to remove. Patience is your friend, I think.

 

I don't understand why you need to remove the plug ....

 

What "plug" are you referring to?

 

I was wondering about the ”plug” comment also.

 

CaptainJaneway is a newbie. Two posts as of right now.

The reference to the "plug" is probably to the baffle in the tube mounted in the valve cover.

 

I wondered if that was what was meant as well.
Removal of the baffle is essentially the entire point of this mod. The baffle clogs up far too easily.

 

I guess im confused of what is required on the 03-04 discos... is it not easy to remove? And what am i drilling out that is metal and can that fall into valve cover?

 

@dparham on 03/04's you need to remove the metal tube lots of penetrating oil and very gently twist,one it starts turning apply upward pressure

 

Remove the metal tube from the valve cover.

Inside that metal tube is a black plastic baffle that has clogged it up and typically causes oil leaks elsewhere on your Disco.

Remove all black plastic from inside that tube by any means. Since it is not in your valve cover after you removed it, there is no danger of metal or black plastic falling into your valve cover.

You can, optionally, drill out that metal tube to make its inner diameter larger. That is not mandatory.

Once that metal is clean+hollowed out such that it is just an empty tube, you can reinstall it into your valve cover and be done with this mod (prefered way is to also insert a new part PCV308 into your air intake on its back side, too).


The new PCV part prevents air from your intake going into your valve cover.

The hollow metal tube prevents oil leaks from over pressure building up inside your valve cover.

 

ok Richard I think i understand lol. the one thing confusing me is what does the hose to the intake connect too after wards ( on the valve cover side) or am I just puling it off of tis piece as it will be sticking out of the valve cover with its top 1/4 cut off with pipe cutter and the hose will slide down over it and maybe a pipe clamp? then at the intake stick on and thread the PVC valve and good to go? tat seems pretty strait forward, I guess not knowing what is under the hose on the valve cover side is confusing most people

Thanks!
Dennis