Pulling my RV behind a logging truck, I decided to pass when he put his flashing lights on. As I was thinking “better shift gears” (I drive a 2007 manual F350) when turbo got to 30 PSI, I heard a big boom followed by a pressure loss noise like a pressure vessel loosing pressure. By that time I was over the hill going down. Next few miles I understood that that noise was not coming from the truck I just passed but from my 6L. Every time my turbo pressure went over 10 PSI I could hear the “phsssss” noise made by escaped pressure. Left the RV in Michigan, it’s Labor Day weekend and I had a mechanic look at it. Found 3 small (3/8” to 1/2") cuts on top of the driver side intercooler bellow just under the air filter. All they could do was epoxy over and I made it, truck only, to Cleveland. By the time I got here I could hear the pressure escaping again when over 9-10 PSI. I see Dorman makes a metal upgrade (steel and 2 bellows) and I will order a set, but the more I look at that bellow I am less convinced that the loud noise and pressure loss I heard could just come from there. What else should I look at? Gee, I hope these things would have been designed with a re-settable pressure valve.Thank you everybody.

 

Is your EGR deleted?

 

EGR deleted? Not that I know of. If it is, could be the EGR valve? Never ask or do it myself. I only hear the pressure loss when the turbo pressure goes up. I bought the truck new and had no problems so far. Just did regular maintenance and got the 85 HP when rebuilt the FICM.

 

Not sure what they tried to fix on the inter-cooler itself, but that does sound like the plastic CAC pipe blowing off (at the end), and then some slime-dog shop telling you they did more than they did. As in: they just put it back on, but didn't address the cracks in that pipe, which is now what you are hearing. Have no clue as to the Doorman part, I bought the Ford metal replacement for the known-to-be-a-problem Plastic up pipe on the CAC. It could be as simple as that...

Scott

 

Dan, I can actually see the epoxy on the part where I saw the cracks. They may not have taken it off, could have more cracks on the bottom... I only payed 75 bucks. Regardless, if you think the plastic cracks do explain the noise, it makes me feel a lot better. At least it could be the only problem. I didn't know Ford makes a metal part; The Dorman Drivers Side Intercooler Pipe was the first one to pop up on google. I would also love to know how could the EGR be related as per Bismic question above.

 

30 psi isn't terribly high, but higher than an 07 stock truck will normally see IIRC.

You might have a dirty/sticking EGR valve or your turbo guide vanes might be sticking.

I would check for codes.

 

I put the gates metal tube kit on my truck to replace the plastic one just because I was in there anyway. It went on nicely and has held up just fine. It's about $90 I think.

 

Thank you Mattdoc88. I’ll look it up. The Dorman is $135, pipe with 2 bellows and 4 clamps. I was hoping that all I have to remove is the air filter; is there more stuff that needs to come out before you get to the intercooler line?

 

I just looked up my list for what the part number is. It's GATES 26100. I got it from rockauto last fall, but they show out of stock now.
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I ordered the Dorman from rockauto, much cheaper than the previous one I found but $7 more than Gates, maybe because it is powder coated black. Can anybody tell me if removing the air filter is all I need to get access to the pipe?

 

 

I've never seen over 22psi on my stock 6.0, you aren't tuned or anything are you? I'd sure be glad that the CAC is blown and the failing point wasn't the head bolts from all that pressure.

Once you remove the air cleaner, it's pretty easy. Just get a good 18" extension and 10mm socket and it'll come right off, you'll have to fish it under the air filter mount, but there's plenty of room down there. I'm actually pulling my tubes today, i have a bad seal somewhere and hiss when i let off the throttle.

 

 

Relax. Its very likely just three CAC tube. Easy fix.

However, 30 psi is an overboost. If memory serves, you should have an overboost error code. Stuck turbo veins could cause that, but there are numerous other potential causes. Do you baby the truck? Once it's warned up, get on it hard a few times to exercise the turbo veins. Your truck needs it.

 

I never got over 20-24 psi, not even when I hammered it getting on the hwy. but I was always in the right gear. This time I was pulling 9000lb RV behind, going up hill and I stayed in the high gear when I decided to pass the truck slowing down in front of me. I glanced at the pressure gage and saw it gets on red at 40. It blew as I was ready to get on the clutch and shift down. I learned something and I'll end up with a stronger line.