Product Details
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Cold Air Intake Kit for the 1997-2006 Jeep Wrangler TJ 4.0L, 2.4L and 2.5L
This Flashark cold air intake kit replaces the factory airbox and intake tube on the 1997-2006 Jeep Wrangler TJ, including the 4.0L inline-six and the 2.4L and 2.5L four-cylinders. A 76mm mandrel-bent aluminum tube carries air to a dry, reusable cone filter held in a sealed steel heat shield, so the intake pulls cooler air than the factory plastic housing and keeps trail dust and water splash off the element. Everything bolts to the factory mounting points with the hardware in the box, no cutting or welding is needed, and most owners finish the swap in about 60 to 90 minutes with basic hand tools.
Specifications
| Specification | Detail |
|---|---|
| Brand | Flashark |
| System Type | Cold air intake (CAI) with an open-element cone filter and a sealed steel heat shield |
| Application | 1997-2006 Jeep Wrangler TJ: 4.0L I6 (AMC 242), 2.4L I4, 2.5L I4 |
| Intake Tube Material | 6061-T6 aluminum |
| Tube Finish | Black powder-coated |
| Tube Diameter | 76mm (3.0") |
| Flare Diameter | 86mm |
| Filter Type | Dry cotton gauze cone filter; washable, reusable, no oil required |
| Heat Shield | Sealed steel, included |
| MAF Sensor Boss | CNC-machined aluminum, 76mm bore |
| Heat Wrap Line | 3/4" x 1,380mm, included |
| Installation | Bolt-on, no tuning required |
| Warranty | 1-year |
Key Features
- 76mm mandrel-bent aluminum intake tube: The 3.0-inch tube replaces the factory snorkel with a smooth, mandrel-bent interior and a black powder-coated finish.
- Dry cotton gauze cone filter: Washable and reusable with no oiling step, which removes the oil carry-over that can coat a MAF sensor after dusty trail runs.
- Sealed steel heat shield: Separates the cone element from engine bay heat and shields it from splash and trail debris.
- 3/4-inch heat wrap line (1,380mm): Wraps the full length of the intake tube to limit heat soak on long climbs and slow summer crawls.
- CNC-machined MAF sensor boss: The factory MAF sensor mounts to a machined 76mm boss in its original position and bore, so it connects to the stock wiring without an adapter.
- Dual mounting brackets (90° and 114°): Shaped for the TJ chassis and fastened to the factory mounting points, so no new holes are needed.
- Multi-layer silicone coupler: A black, heat-resistant coupler sealed at each tube joint with stainless T-bolt clamps.
- Bolt-on installation: All mounting hardware is included, no cutting or welding is required, and the swap runs about 60 to 90 minutes with basic hand tools.
Who This Kit Is For
This Flashark cold air intake kit is built for the 1997-2006 Jeep Wrangler TJ with the 4.0L I6, the 2.4L I4, or the 2.5L I4 engine. It is aimed at TJ owners who want cooler intake air on trail and highway drives, a filter they can wash instead of replace, and a bolt-on install they can do in the driveway with hand tools.
For you if:
- You run a 1997-2006 TJ and want the restrictive factory airbox and intake tube out of the airflow path.
- You spend time on dusty trails and want a dry filter that does not need oiling.
- You want an intake that mounts to the factory points and can be reversed with basic tools.
- You want the throttle response to feel sharper in the 2,000-4,000 RPM range where the TJ does most of its work off-road.
- You want a direct-fit part rather than a generic one-size-fits-nothing kit.
Not for you if:
- Your Wrangler is a 1987-1995 YJ, a 2007-2018 JK or JL, or a Cherokee XJ. This kit does not fit those platforms.
- You need a stock replacement paper filter or a factory intake hose rather than an intake upgrade.
- You expect a measurable fuel economy gain from an intake alone.
- You live in California or another CARB-adopting state and need an emissions-exempt part; this kit carries no CARB Executive Order (see Check Before Ordering).
- You ford deep water regularly without a relocation or high-mount solution.
Running a different Jeep platform or model year? Browse the full Jeep Cold Air Intake Kits line to find the fitment that matches your year and engine.
Check Before Ordering
Work through these six points before you place the order. Getting the year, engine and emissions details right takes a minute and avoids a return shipment.
1. Vehicle fitment. This kit is a direct fit for the 1997-2006 Jeep Wrangler TJ: the 2.5L I4 from 1997-2002, the 4.0L I6 (AMC 242) from 1997-2006, and the 2.4L I4 from 2003-2006. It does not fit the 1987-1995 Wrangler YJ, the 2007-2018 Wrangler JK or JL, or the Cherokee XJ. Trim level does not change the fitment: Sport, Sahara, Rubicon, SE, X and Unlimited are all covered inside those year ranges. If your TJ falls outside this list, message us with your VIN and engine code before ordering.
2. Intake type. You are getting an open-element cone filter with a sealed steel heat shield, plus a 76mm aluminum tube, rather than a fully closed airbox. That layout is what the sealed heat shield is there for: it shields the element from engine bay heat and from splash while keeping the intake path short and direct.
3. Filter and maintenance. The filter is dry cotton gauze, so there is no oil to apply and no re-oiling interval to track. Clean it when the pleats look loaded, following the care steps for a dry element, and let it air dry before refitting it.
4. Sensors and tube size. The factory MAF sensor mounts to the CNC-machined 76mm boss in its original position and bore, and the tube measures 76mm (3.0") with an 86mm flare. The kit keeps the factory sensor and its wiring, so no adapter is required. Recheck the sensor connector and every clamp after the first drive to confirm nothing has worked loose.
5. Emissions status. This kit does not carry a CARB Executive Order. It is not legal for sale or use in California (and other CARB-adopting states). If you live in a state that follows CARB rules, confirm what your registration and inspection requirements allow before buying.
6. Installation and water crossings. Plan on about 60 to 90 minutes with basic hand tools and no cutting or welding. The cone element sits in the engine bay, so avoid deep water crossings: water ingestion can hydrolock the engine and cause severe damage.
While the hood is open, it is also worth checking the plastic coolant reservoir on a TJ of this age, since the originals crack and discolor over time. If yours has seen better days, a direct-fit replacement is available: Aluminum coolant reservoir for 1997-2006 Jeep Wrangler.
What's in the Box
- 1x 76mm aluminum intake tube (black powder-coated)
- 1x Dry high-flow cone air filter (red top / black base)
- 1x Sealed steel heat shield
- 1x 3/4" heat wrap line (1,380mm)
- 1x Straight rubber sleeve (70mm)
- 1x Silicone breather hose (240mm)
- 1x Crescent mounting bracket
- 1x 90° mounting bracket
- 1x 114° mounting bracket
- 2x T-bolt clamps (59-82mm)
- 2x Small hose clamps
- 1x Installation hardware kit (all bolts, washers, grommets and fasteners)
Your factory MAF sensor and its wiring carry over to the new tube, so they are not part of this kit.
Shipping & Returns
Free U.S. Shipping: Orders are typically processed within 1–2 business days and delivered within 7–9 business days. Additional charges may apply to remote areas.
30-Day Returns: Unopened and unused items in their original packaging may be returned within 30 days of receipt. Return shipping is covered for verified quality issues.
Worry-Free Delivery: Optional protection against eligible loss, theft, delay, or transit damage is available at checkout.
| Year | Make | Model | Engine |
|---|---|---|---|
| 1997-2002 | Jeep | Wrangler TJ | 2.5L I4 |
| 1997-2006 | Jeep | Wrangler TJ | 4.0L I6 (AMC 242) |
| 2003-2006 | Jeep | Wrangler TJ | 2.4L I4 |
Note: Does NOT fit 1987–1995 Wrangler YJ, 2007–2018 Wrangler JK/JL, or Cherokee XJ. All trim levels (Sport, Sahara, Rubicon, SE, X, Unlimited) are covered within the listed year ranges.
1997-2006 Jeep Wrangler TJ Cold Air Intake FAQs
Q1: Is this cold air intake legal in my state?
A1: This kit does not carry a CARB Executive Order, so it is not legal for sale or use in California (and other CARB-adopting states). If you are outside those states, check your local inspection and emissions rules before installation, and keep the original airbox parts if you may need to return the intake system to stock.
Q2: Will this fit my 1997-2006 Jeep Wrangler TJ?
A2: It fits the TJ with the 2.5L I4 from 1997-2002, the 4.0L I6 (AMC 242) from 1997-2006, and the 2.4L I4 from 2003-2006, and trim level does not change that. It does not fit the 1987-1995 Wrangler YJ, the 2007-2018 Wrangler JK or JL, or the Cherokee XJ. If your year and engine are outside those ranges, send us your VIN before ordering and we will confirm fitment for you.
Q3: Why replace the factory airbox on a 1997-2006 TJ?
A3: The 4.0L AMC straight-six is a durable, torque-focused engine, and the factory airbox is a flat plastic housing with a paper element that loads up quickly in trail dust and pulls air from a hot engine bay. Replacing that housing and intake tube with a 76mm mandrel-bent tube, a dry cone filter and a sealed steel heat shield puts a larger, washable element in a cooler, shielded position instead of behind a paper panel filter.
Q4: How much horsepower will this add?
A4: Typical intake-only gains for a naturally aspirated application like this are approximately +3-10 hp and +3-10 lb-ft. Actual results depend on the vehicle, its calibration, the quality of the installation, and any supporting hardware already fitted.
Q5: Will this cold air intake improve my MPG?
A5: Fuel economy is dominated by driving habits, gearing and tire size, and an intake alone can't guarantee a measurable gain. The clearest everyday difference from this kit is throttle response and intake tone rather than fuel economy.
Q6: Will this void my warranty?
A6: Under the Magnuson-Moss Warranty Act, an aftermarket part cannot void your factory warranty unless it is proven to have caused the failure. This kit is designed as a direct bolt-on replacement that keeps the factory MAF sensor, its position and its connections.
Q7: Will it throw a check engine light (CEL)?
A7: The kit is designed to retain the factory MAF sensor in its original position and bore, which keeps the sensor signal inside its stock calibration window. When a light does appear after an intake install, it is usually an air leak at a tube joint, contamination on the sensor element, or a connector that was not fully seated. See what a rough idle after a cold air intake install usually means, and the 7 checks that fix it.
Q8: Do I need a tune after installing this intake?
A8: No tune is required. This is a bolt-on kit that keeps the factory MAF sensor in its original position and bore, so the ECU continues to read airflow from the sensor it was calibrated for.
Q9: What does the heat wrap line on the tube do?
A9: The 3/4-inch heat wrap line runs the full 1,380mm length of the aluminum tube. Wrapping the tube limits heat soak during long climbs and slow summer crawls, when under-hood temperatures climb and a bare metal tube would otherwise absorb that heat on its way to the throttle body.
Q10: Is this safe in rain or deep water?
A10: Normal rain driving is fine, and the sealed steel heat shield keeps road splash off the cone element. Avoid deep water crossings: the filter sits in the engine bay, and water ingestion can hydrolock the engine and cause severe damage. If you ford water regularly, consider a high-mount or relocation solution instead.
Q11: How do I clean the filter?
A11: This is a dry cotton gauze filter, so there is no oil to apply. Clean it when the pleats look loaded, rinse and air dry the element thoroughly, then refit it and confirm the clamp is tight. Because the element is dry, there is no oil carry-over to coat the MAF sensor. Our step-by-step guide to cleaning a cold air intake filter covers the full process.
Q12: What is included, and what do I still need?
A12: The box contains the 76mm aluminum intake tube, the dry cone filter, the sealed steel heat shield, the 3/4" heat wrap line, the straight rubber sleeve, the silicone breather hose, the three mounting brackets, two T-bolt clamps, two small hose clamps and the installation hardware kit. Your factory MAF sensor and wiring carry over from the original intake, and you will need basic hand tools.
Q13: What does it sound like?
A13: You will hear a deeper induction tone under acceleration, and it settles down at steady cruise. Sound is subjective, so if maximum intake volume is what you are after, an open-element short ram style intake is the louder route; this kit is set up with a sealed heat shield around the element.
Fast Shipping Policy
Your order will be dispatched within 1-2 business days, and the package will arrive within your order's estimated date. Click for Shipping Policy
Easy Return Policy
Every order comes with a 30-day free return, provided the item is brand new, uninstalled, and in its original packaging. We cover return shipping for quality issues. Refunds are processed within 3-5 business days. Click for Return Policy
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