First a brief background:
I had a 2004 F-250 with 6.0 ltr, was on the road to go camping, got 5 minutes away from home with my 8000lb fifth wheel when i got a loud pop and lost all power. A quick inspection under the hood revealed that the charge air piper (intercooler pipe) had blow off the intercooler. The pipe didn't burst or anything, it just blew off the intercooler. I went out, picked up a worm gear clamp and reattached it to the intercooler pipe. From there everything was tickety boo and off I went. 2 days and 400KM later I'm on my way home and I ran into big issues with losing power which in the long run turned out to be 3 burnt up injectors and an HPOP failure.

I don't know if one thing had anything to do with the other or if it was just a coincidence.

Fast forward to last week and I'm on my way to go camping pulling my 13000lb fifth wheel with my 2012 deleted F350 6.7ltr, engine was replaced with a motor out of a 2016 f350 roughly 20000KM ago. after about 1 hr on the road I get a loud pop as I'm going up a hill and I look in the rear view to se that I'm blowing out huge clouds of black smoke out the exhaust but no engine codes or trouble lights.
I check and sure enough the hot side charge air pipe is blown off. Again I pick up a ring clamp and put it on there, take it for a test drive and its fine but as soon as I go into heavy acceleration it blows off again. The original clamp is more of a compression ring as apposed to a worm gear clamp, I'm sure for a reason, and its very possible that I didn't tighten the clamp enough as I was afraid of over tightening and damaging the intercooler or cutting the pipe itself.

I have ordered an aftermarket upgraded charge air pipe but I have that nagging voice in the back of my head that says there is a reason it is blowing off and there is more to it than just changing the pipe. Does anyone have any experience/Thoughts on this? I know there is some pretty good pressure in the pipe under heavy load but I'm afraid to take it on a trip and burn up a bunch of injectors again. I checked the gauges and under heavy acceleration it seems to be topping out at around 20lbs of boost which is right in the middle of the gauge as it goes up to 40 so I don't think its an abnormally high amount of boost, certainly not enough to be blowing the tube off.

 

Is there a way to put on two clamps?

 

I could put on a different kind of clamp and yes there is enough room to add a second clamp but my concern is more around the question of whether I'm treating the disease or the symptom.

I've ordered an after market intercooler pipe and will be putting it on but I'm more concerned about whether the pipe blowing off is the sign of a bigger problem that is going to lead to other failures if it isn't addressed and I just change out the intercooler pipe.

 

I'd say the disease is the clamp is not tight enough. Can't imagine what else it could be.