I have a 2003-350/4x4/crewcab/shortbed. A 06-03 build date.I have 9500 miles on it . I tow a 28.5ft fith wheel. I've blown the side of the intercooler off twice, the hose comming off the turbo one time. It has had all three updates. I was just wondering if anybody else is having this problem or know why this is happening???? Oh my mileage is really bad [about 10], and no power up hill,and it has had the rear main replaced once.

 

Johndeer,

Are you saying the intercooler came apart twice and had to be replaced or that the hose came off the intercooler side twice.

If the Hose has come off three times, (twice on the intercooler side and once on the turbo side), there is a TSB out that details the fix.

Also since you say you have no power up hill, you may have a problem with the turbo or the VGT sensor not operating properly. This may also be causing an over boost situation, and thus the intercooler hose blow off. I would have these checked out by a knowledgeble 6.0 tech.

As for gas mileage, is this loaded with the trailer traveling up hill and down or is this your empty, with no trailer mileage.
If it is your loaded towing mileage depending on conditions, driving style, gearing etc, 10mpg could be in the normal range. It is hard to say for sure not knowing truck gears and your loaded GCVW.

Hope this helps

 

Hose maybe!

 

There should be a way to double clamp the intercooler hoses, we had to do that to a buddy's 7.3 truck after it kept blowing intercooler hoses, this was after we put a 110hp superchip and took off the waistgate lol

 

If it is the hose any and I mean any oil film can cause it to loosen up.
Clean both parts with break clean and replace, make sure clamp is on stright.

 

I just picked my truck up, they replaced the intercooler,and the turbo this time. You should have seen the turbo,it was shot. Half the vains were gone,the thing was toast. My truck now seem to have some of its pep back,will find out for sure when I pull the trailer.
Yes it was the intercooler itself. It would blow the side off of it on the left side,and the hose once comming off the turbo itself. The turbo was putting out 30-32 lbs so the computer was leaning out the motor tring to correct the problem,something like that? Any way we will let you all know how it comes out with the trailer next week
Thanks for all the input

 

Good thing it is OK now.........with pep again.
This was a new one in the problem catagory

 

For something that can spin up to 150,000 RPMs, I am suprised that the entire turbine wasn't destroyed. When a turbine blade breaks off for whatever reason, the entire turbine becomes unbalanced. When its unbalanced, pieces start flying. A turbo that has suffered catastrophic damage is not pretty.

An intercooler coming apart? Wow, never heard of that happening. I have heard of blowing boots and hoses off, but never an intercooler coming apart. Dang.

 

I think in this case the turbo bumping up so high ultimately caused the intercooler to come apart like a cheap suit in a rainstorm……….the cause and affect syndrome, works every time.

 

I still have not had time to pull trailer yet, with new turbo. Just thought I would let you know that my mileage, yet not great is 12.5 and hopefully climming since new turbo. I tried to get the dealer to take a picture of the turbo and send it to me so I could show it to you, but guess he couldn't find his camera. Will still let you know how it does as sone as i tow with it.

 

He probably did not want to give you the picture.........IMO