Intercooler Pipes and Boost ? - Ford Powerstroke Diesel Forum
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Old 03-23-2012, 10:01 AM Rookie

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Intercooler Pipes and Boost ?

So I sold my 99 7.3 6spd with 150,000 and moved into an 04 with the 6.0 6spd and 100,000 miles. It had the turbo replaced by Ford when only 9 months old. It has had the downpipe replaced with a bigger one, muffler deleted, Converter had the contents smashed out of it with a pipe and reinstalled, K&N filter charger kit added, and a superchips tuner installed. Also within the last 6 months has had the turbo taken apart and cleaned and lubed and the EGR delete kit installed (the EGR had been unplugged since new). The problem is that it can only be run on the low or tow setting of the tuner or it makes so much boost it blows the rubber connecting hoses off the intercooler pipes. It has no problem making 35 PSI. Former owner carried spare hoses under the back seat. Even made two extra clamps and put around the pipes and attached to the engine to help hold them from moving so much in an effort to keep it from blowing apart. I would like to at least turn the tuner up to the middle setting but really don’t want to be installing new hoses on a hot motor along the road all the time, especially at $100.00/hose. The truck even has a couple small dents in the hood that go up from the pipes blowing off so hard and hitting the hood. The truck does run and pull good, but I would like to get a little bit more out of it, but it sucks when you have to constantly watch the boost gauge and back out of it when pulling a hill for fear of a hose blowing off. Any suggestions on what I can do to keep from blowing intercooler hoses?
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Old 03-23-2012, 11:20 AM
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Well i don't see ARP studs anywhere in your post and 35lbs boost the max on a motor with head bolts is 28lbs but this may help
If you are having a problem keeping the boots on something like this may help plus the boots must be clean free of oil.
CAC Tube Brace - TCN Enterprises
2 stroker
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Old 03-23-2012, 11:21 AM
War is the answer!


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I run 34psi and I have never had an issue blowing hoses off. Try taking all of them off and cleaning them with cleaner. Also make sure they are tightened down really good. Also look into the CCV mod.

Last edited by WarChild; 03-23-2012 at 11:24 AM.
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Old 03-23-2012, 11:34 AM
Emergency Services

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I heard that using hairspray helps keep the boots on
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