Blown intercooler?? - Ford Powerstroke Diesel Forum
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post #1 of 17 Old 04-12-2019, 03:09 PM Thread Starter
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Blown intercooler??

I was driving home from work today when all of a sudden while accelerating from a light I heard a huge whooosh come out from under the hood and lost boost. It still drives but when it gets to around 15-20 psi I can hear it leaking out from somewhere, of course the more it tries to build boost the louder it gets. I pulled the metal charge pipe and checked the coupling hoses and they both are in great shape with no cracks or holes. Could it be coming from the intercooler itself?? It’s absolutely completely stock ‘05 6.0 with 98,000mi.

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post #2 of 17 Old 04-12-2019, 04:06 PM
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It could be but it's not likely. I'm betting it's one of the boots. When you build enough boost it's probably escaping around a clamp somewhere.



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post #3 of 17 Old 04-12-2019, 05:04 PM
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Split cold side plastic pipe. Probably at the lower end. < most likely IMO

Could be a leak at the plastic tanks on the intercooler too.

Could be a hot side boot

Could be something else.
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post #4 of 17 Old 04-12-2019, 05:14 PM Thread Starter
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I’m going to check the cold side in the morning. I took the hot side off and everything looked good with no holes or cracks in the pipe or boots. I’m just hoping it not the actual intercooler itself.

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post #5 of 17 Old 04-12-2019, 08:18 PM
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If it's the cold side, your best bet is to upgrade to the metal one. However, if you don't want to do that, I have a plastic one sitting in my garage doing nothing from when I upgraded that I would sell ya a heck of a lot cheaper than anywhere else.

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post #6 of 17 Old 04-13-2019, 05:53 AM
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If you get a 4" rubber cap and air compressor connections, you can charge up to 10 PSI and find the leak real quick. DieselSite sells them, or it is something if you're handy you might be able to build yourself at home depot.

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post #7 of 17 Old 04-13-2019, 11:57 AM Thread Starter
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Pulled the cold side off and there’s a small crack by the intercooler. Looks like I’m upgrading.

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post #8 of 17 Old 04-15-2019, 03:26 AM
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Quote:
Originally Posted by 027.3 View Post
Pulled the cold side off and there’s a small crack by the intercooler. Looks like I’m upgrading.
Same thing happened to me. I have an extra brand new Spearco cold side metal pipe and boots in my garage I am willing to sell for cheap if you're interested. PM me if you are.

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post #9 of 17 Old 04-15-2019, 06:36 AM Thread Starter
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Quote:
Originally Posted by Chris View Post
Quote:
Originally Posted by 027.3 View Post
Pulled the cold side off and there’s a small crack by the intercooler. Looks like I’m upgrading.
Same thing happened to me. I have an extra brand new Spearco cold side metal pipe and boots in my garage I am willing to sell for cheap if you're interested. PM me if you are.
Thanks man but I’ve already got one coming from riffraff.

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post #10 of 17 Old 04-15-2019, 07:54 AM
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Quote:
Originally Posted by G8orFord View Post
Split cold side plastic pipe. Probably at the lower end. < most likely IMO

Could be a leak at the plastic tanks on the intercooler too.

Could be a hot side boot

Could be something else.
was going to say this then saw you had a 7.3


Quote:
Originally Posted by 027.3 View Post
Thanks man but I’ve already got one coming from riffraff.
obviously i am late to the party and can offer o further assistance...
BUT...
is this an 02 or 05-07 we are talking about here and i missed something
i need more coffee

I like mead
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