Ford Powerstroke Diesel Forum banner

Intercooler Pipe Boot Failure

1 reading
5.9K views 14 replies 5 participants last post by  Heavy_GD  
#1 ·
Last Friday night I was driving down the highway and I was going to pass someone and as I did I got on the throttle a little bit about 3000 or so RPM to pass the guy and as I did I hear a loud KA-BANG! I didn't loose any speed as well as I didn't see any smoke or anything like that but hear a loud rushing of air from the turbo plus a loss of power. I limped it off the next exit to investigate and I pop the hood seeing the intercooler popped off. Not knowing the failure rate and thinking due to the fact I removed it that day to investigate the EGR delete for possible leaks that it must have popped off because it was too loose so I tightened her up and went down the road only for it to do it again minutes later. At that point I tightened again and by the time I got to my destination you could hear air leaking slightly so I popped the hoods to see it slipping off again. I would like to know a proper way to fix this, do I replace the silicone boot? do I replace the clamps? (If I do, can I use regular hose clamps or must I use the kind of clamps they have on there?) How tight must I make them? and what kind of tool should I use? (a regular hand wrench or a torque wrench?)

Thank you


I need feedback on this one please.
 
#3 ·
I had the same issue, kept blowing off different hoses from the turbo to the intake. My fix was double clamping the boot at the intake and replacing the stock clamps with aftermarket clamps that don't have a spring on them. After that I haven't blown off a boot since, 6+ months now.
 
#7 ·
I admit loosening and tightening the bolt a bit lately because of looking for coolant leaks but I just cant decide where to start. my roommate says "oh put an extra hose clamp on it and it will be fine" also fatbastardf350 I have no access to a welder so obviously that is out of the question. I will start with cleaning the boot and inspecting the clamp for damage. Just gotta know what to look for in that aspect.
 
#8 ·
Ok. I took the pipe boot off and it had some grime in it so I scrubbed it clean and put it back on. I realize last time I may have over tightened the clamps. This time I made sure they were tight but not too tight. Seems to be doing the trick. I'll go out and give her a WOT run soon to see.
 
#9 ·
A thin smear of RTV can be semi permanent fix if you cant spring for new boots. Keep in mind you have to let it cure and it can be a real bear getn em off again intact
 
#10 ·
Ya i dont think i am going to try that. Ill just go to ford and get a new boot and clamps if it keeps continuing. Only thing is a question i asked earlier. Must i use a torque wrench? Or a regular wrench to tighten the nuts?

Thank You
 
#11 ·
A torque wrench is always the surefire way to go. If you've still got the spring clamps its only 60-75 in/lbs
 
#12 ·
Ok. I took it to a diesek shop. They say the clamp was in the wrong position on the hose as you were supposed to tighten over the groove. They tightened it and I drove home about 20 mi away. And when I got back the gap between the rubber and the pipe had increased slightly. I am not sure what a normal gap is but I'm not comfortable with the fact it expanded. Also I try to give it WOT and the turbo would boost more and really quickly while the RPMs would be quite hesitant. But it is running great so I'll put it that way