Overboost issue - Ford Powerstroke Diesel Forum
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post #1 of 7 Unread 07-29-2019, 05:48 AM Thread Starter
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Overboost issue

I have an early 04 6.0 with 4" turbo back exhaust, egr cooler delete and coolant bypass filter otherwise stock. Blew the side off the intercooler pulling around 7k and keeps blowing rubber coupler off. Anyone else had this issue? Suggestions on a fix?
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post #2 of 7 Unread 07-29-2019, 06:26 AM
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Very common issue. One way is to clean the boot with something like simple green and replace. Also, I have used aqua net extra hold hairspray; install wet, and torque down, and then it dries like a glue. The best thing to do is to get a new set of boots. A couple of options. I went with dieselsite.

2005 F250, 189,000 Miles
Bullet Proof HD Oil Cooler w/ Cold Weather Kit, Bullet Proof EGR, Bulletproof Water Pump, 7.3 Fan Clutch
Airlift 5k Airbags and Wireless Air
Edge CTS w/ EGT probe and Fuel Pressure Sensor.
15 MPG slick; 10 MPG towing 11k fifth wheel
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post #3 of 7 Unread 07-29-2019, 06:39 AM Thread Starter
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I should have specified about the intercooler it blew the side off the intercooler where it is crimped to the cooling fins
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post #4 of 7 Unread 07-29-2019, 08:13 AM
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With this, someone is going to recommend a metal intercooler. Some of the OEM plastic intercoolers are prone to what you mentioned. I did not have the intercooler cracking problem, yet.

For my CAC boots, I bought but have not installed the Dieselsite metal O-Rings. Those get installed between the metal pipe and rubber Boot. Supposed to not need these until the boost gets above 50, but I have a pair in case the boots pop off coming down the road again.

2005 F250, 189,000 Miles
Bullet Proof HD Oil Cooler w/ Cold Weather Kit, Bullet Proof EGR, Bulletproof Water Pump, 7.3 Fan Clutch
Airlift 5k Airbags and Wireless Air
Edge CTS w/ EGT probe and Fuel Pressure Sensor.
15 MPG slick; 10 MPG towing 11k fifth wheel
Ravelco

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post #5 of 7 Unread 08-17-2019, 08:28 AM
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ya, im having this problem too, have a scangauge II and what im noticing is that under load and at WOT the boost on my scangauge is going negative, then boom! wondering if its a problem with overboost ? something blocked in intake manifold? ive changed boots twice now, first time ford boots and clamps (mistake) and then bought the mishimoto boots and clamps. also used hairspray. same thing. always on hot side. anyone have any recommendations before i tear the whole top of the motor off to look for blockages?
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post #6 of 7 Unread 08-17-2019, 12:55 PM
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Quote:
Originally Posted by Jmcdaniel046.0 View Post
I should have specified about the intercooler it blew the side off the intercooler where it is crimped to the cooling fins
Missed the intercooler breaking in my last post. The plastic cooler has been known to burst like that. There’s a few metal inter coolers for replacement. May be the intercooler, hot side cCAC pipe and boots need changing.

Also, if there was something wrong with the MAP sensor, most usually the hose has holes, than the pressure reads less than usual and I guess the turbo could work harder than it needs to. Might want to check the MAP hose which is easy prior to opening up the engine.

2005 F250, 189,000 Miles
Bullet Proof HD Oil Cooler w/ Cold Weather Kit, Bullet Proof EGR, Bulletproof Water Pump, 7.3 Fan Clutch
Airlift 5k Airbags and Wireless Air
Edge CTS w/ EGT probe and Fuel Pressure Sensor.
15 MPG slick; 10 MPG towing 11k fifth wheel
Ravelco

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post #7 of 7 Unread 08-17-2019, 04:41 PM
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right on, ya ill start replacing parts there. i appreciate the help
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