losing intercooler pipe clamps HELP - Ford Powerstroke Diesel Forum
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Old 09-10-2013, 11:36 AM
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losing intercooler pipe clamps HELP

04 F 250
6.0
Banks 6 gun set on 2
K&N filter
Stock motor guts except for 06 EGR and coolers installed

I have started to notice that if I get on it a little then let up for a turn when I hit the throttle again it kind of takes a few seconds before it gets going again. The turbo is not spooling up as it normally does. Once it does the truck runs great. I was getting some parts for my 65 and turned right onto the hwy, gave it 3/4 throttle and a loud boom then a whistle....
Pulled off the road, the truck is still running and popped the hood. The clamp for the drivers side intercooler pipe is gone and the pipe is hanging loose from the rubber sleeve. The sleeve is still clamped to the intercooler though.
Limp the truck home the 3 miles slowly...
Just put a new clamp on and took a test drive. The same hesitation as described above and when I punched it it blew the same clamp off.
Any ideas????

Really don't have the money to take this anywhere with a new baby in the house.
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Old 09-10-2013, 11:52 AM
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Quote:
Originally Posted by vannutz View Post
04 F 250
6.0
Banks 6 gun set on 2
K&N filter
Stock motor guts except for 06 EGR and coolers installed

I have started to notice that if I get on it a little then let up for a turn when I hit the throttle again it kind of takes a few seconds before it gets going again. The turbo is not spooling up as it normally does. Once it does the truck runs great. I was getting some parts for my 65 and turned right onto the hwy, gave it 3/4 throttle and a loud boom then a whistle....
Pulled off the road, the truck is still running and popped the hood. The clamp for the drivers side intercooler pipe is gone and the pipe is hanging loose from the rubber sleeve. The sleeve is still clamped to the intercooler though.
Limp the truck home the 3 miles slowly...
Just put a new clamp on and took a test drive. The same hesitation as described above and when I punched it it blew the same clamp off.
Any ideas????

Really don't have the money to take this anywhere with a new baby in the house.
Pull the boot off, wash it with dawn soap throughly. Place it back on, clamp down. The reason why it won't stay now is because it is covered in oil.
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Old 09-10-2013, 12:06 PM
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but would the oil cause the clamps to break?? I have not found either one when they broke off. Wasn't sure if the cooler can get clogged?? Or maybe the turbo vanes sticking would cause such a backpressure??
Thanx
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Old 09-10-2013, 03:21 PM
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The clamps useually dont break they run away when the boot blows off. The oil film will keep the clamp from evenly distributeing clamp load. Cac ruptuer does occur but kinda rare, too much oil flowing thru the cooler will coat the tubes dust will then stick to the tubes and cause restriction.

The factory boots were infamous for blowing off they were made of akinda flimsy fire hose kind of material, oil saturation would weaken the material and it would also tear and split.
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Old 09-10-2013, 03:30 PM
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thanks for the info. I will clean them up and try again
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Old 09-10-2013, 05:12 PM
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Another trick you can try is after cleaning spray the pipe & inside hose with cheap hair spray, let dry some and reassemble.
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Old 09-18-2013, 06:20 AM
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Yep second that, I took my pipes off when I was doing the keyhole gasket and FPR spring and shortly after reassembling I lost the upper pipe and unfortunately the clamp hit my hood so hard it dented it up from the inside (small dent but still). I very thoroughly cleaned the pipe and the inside of the boot and put it back on and I've had 10's of thousands of trouble free miles since. I know from working on sport compact cars before that the hairspray trick works great too. goes on slimey and dries sticky.
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Old 09-22-2013, 07:10 PM
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I've blown the hose off my turbo too many times to count. Maybe I'm lucky but I have always found it, some wheres under the hood. never seen 1 break yet. now if it was stupidly overtightened breaking is a possibility. brake clean then hairspray. there certainly is a possibility that you also have a turbo vane issue, but without a boost gauge, it's fairly hard to tell. If it is over boosting, and the hose is glues on, there is one less weak link to fail before something bursts. Hopefully only a boot, if sticking is an issue
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