I finally decided to can my AFE intake and take the hit of wasted money for that piece of shit. Looking back, I've had nothing but bad experiences. First it wasn't designed for the 02-03 B6 so that presented the first problem with installing it in the first place. Second when I installed my K04, I noticed that the way the TIP has to be crammed in there, it caused the hose clamp to cut the TIP to turbo coupler a good 2/3 of the way around cause a huge leak. I was able to fix that with a silicone coupler from the hardware store, which, when I went to install my Blinktek heatshield, I noticed was also sliced and now causing a huge TIP leak. Thirdly, also when installing the K04, I noticed that the "plug" section of the grommets for some of the TIP connection(as in the part the actually seals, not the ring you can see from the outside) where also destroyed and no longer there. I noticed this again while working on it today. This leads me to believe that both grommets went through the spin cycle and that could have been what made my K03 shit out to begin with.
With all that said, I have decided to scrap the Afe intake and get a more reputable TIP, and modify pieces of the Afe to create a custom cone-filter intake. I was thinking of going with the Forge TIP because I recall it being the cheapest, while still getting the job done.
On a side note, after today's TIP leak, my boost has not been the same. When everything was "fine" it would peak at 26 and hold at 22. I always felt that was a little high for REVO 2, especially since they didn't change the Boost/Timing after the K04. Now it is spiking to 24 and holding at 21. The only reason I find that strange is when I first installed the K04 and had the first TIP leak, it would still spike to 26.
On a positive note, the heatshield seems to have eliminated the knock I was getting(then again, that's probably more due to the fact that I'm not boosting as high). Sorry this was kind of a rant too. Finally have to give props to Matt and his Blinktek heatshields in the classifieds cuz it was great working with him and the product has made a significant difference.
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