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Old 07-11-2013, 11:05 AM
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help - blew out intercooler piping + thick black smoke

Hello all,
I have a 2012 F350 6.7L with H&S tuner AFE DPF & EGR delete with turbo back 4" exhaust. I was running the "wild" tune and pulling a 10k trailer up a steep grade floored and BOOM. Total loss of power and pouring thick black smoke. Prior to this my truck smoked if I really got on it until I did the EGR delete. After the EGR delete you could really lay on it and only see a little black cloud. I pushed it up the rest of the hill with no power and pulled over. Checked all the boots, everything was attached and looked good. I couldn't find what was wrong. I limped to an auto shop that had some tools and found one of the intercooler pipes had a huge blowout right where the sensor is. I taped it up with duct tape and heat tape over that and drove the rest of the 3 hrs home trying to keep it under 15lbs of boost. A lot less smoke, and mostly only when its high boost. I checked everything over today and I was about 1gal low on coolant and it popped the sensor out and made a much smaller hole in my duct tape patch. It looks like the coolant line on the top of the intercooler was leaking (theres a big stain under it). I re did the temporary patch till the replacement comes in.
My question is, why am I still blowing black smoke under boost? What do you think I did? What should I look for? How can I fix this? Thanks in advance

leopard duct tape patch job
http://imgur.com/Gk7cysT
a shot of the intercooler leaking coolant (I think)
http://imgur.com/HD8MAeC
redone patch job
http://imgur.com/yyttsT9
Video of the smoke
http://youtu.be/GAEC3XfXPPo

Last edited by yupitsnuge; 07-11-2013 at 11:11 AM. Reason: added pics & video
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Old 07-11-2013, 11:16 AM
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Well problem number one, why are you pulling 10K pounds on that hot of a tune? You are lucky you didn't go into full melt down. Most likely you are still losing air somewhere and thats why you are blowing black smoke.

I'd stop driving it until you know exactly whats wrong and fix it right. Second I'd stop towing 10k pounds on a hot tune.
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Old 07-11-2013, 11:29 AM
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I was towing on the hot tune because of the better gas milage when you stay low RPM's. The H&S mini maxx gets much better gas milage on the "wild" tune then "no power" tune when you dont push it.
I was an idiot and my buddy in his chevy was towing next to me and I floored it to blow by him. Truck always ran like a top, no problems. I pushed it too hard, lesson learned. Now I just want to fix it. Where else should I look for a possible leak?
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Old 07-11-2013, 12:02 PM
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I should also add that before the intercooler piping blowout I was running 600's EGT's normally towing and after I am running 1100-1200's regular towing.
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Old 07-11-2013, 12:11 PM
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I had the same thing happen while I was snow plowing.

CHARGE AIR COOLER TUBE BLOWS!

I used two hose clamps and some pieces of rubber I had laying around the house to fix it. Held up for 8,000 miles so far.

-Pete
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Old 07-11-2013, 02:58 PM
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i also have a coolant leak out of the tank closer to the air filter
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Old 07-11-2013, 03:09 PM
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Old 07-11-2013, 05:07 PM
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welp I found the secondary coolant system leak...
imgur: the simple image sharer

damn H&S EGR crapola block off rotted out in less than 4 months!!!
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Old 07-11-2013, 05:09 PM
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Although i would never tow @ high loads with a hot tune in, its your truck, knock yourself out. That being said, duct tape and heat tape is NOT going to seal off a blown hose, quit driving it until you get the hoses reliably repaired/replaced. Do not nuke your 60K dollar trucks engine cause you are trying to fix it with duct tape!.
Lots of black smoke and high EGT are most likely trying to tell you that u have insufficient air, maybe from the duct taped hose... Get it fixed, replace the sensor if damaged, and inspect the throttle valve to make sure its going wide open.( not sure if its even in play anymore with the delete tunes?)
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Old 10-17-2013, 07:07 AM
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We have found the best way to fix the charge pipe problems is to replace the OEM plastic piece with an aftermarket one:

11-14 Ford 6.7L Intercooler Pipe Upgrade Kit - Ford

Too many people have been left stranded, replace it before yours fails.
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