This past weekend while towing the intercooler tube (from the intercooler to the neck that leads to the throttle blade) popped off. This was after roughly 16 hours of towing a 48' enclosed car trailer from south Florida up through I-75 and the mountains. It appears that there is some oil residue on the inside of the piping and that along with the boost caused it to pop off. We cleaned it with brake cleaner and put it back on. It never popped off again but every stop we made we checked it and cleaned it up just so it didn't happen on an incline while towing.

Any ideas if this is common or if there are any ways to fix this? This same issue happens on my buddies 7.3L truck but his is just 10 times harder to get to.

The truck is an 04 F350 Auto with a diablo predator on the towing tune and now 12K miles.

Bill

 

I have lost mine two times, IMO no big deal. Pain in the butt, always towing.
Clean it with brake clean not carb cleaner, and do both parts. The clamps, OEM ones,
I tighten more than the stock setting. I also go with a .375 wide European type worm clamp.
I use the foreign..…because they are very good and not wide allowing for more pressure than the ½ wide style clamp.
I have not lost one…………again. And I have no tuner.....all stock.
It is imperative to clean it well, when you do one you might as well do them all and torque a bit more……..IMO.

 

I think there is a service advisory for this... and basically the clean and remount in a new way is the gist of it...

 

I have also had this happen on my 03 F550. It was the blue rubber connector coming out of the pressure side of the turbo. Not towing though just accellerating up an on ramp. Given my rig weighs 19,500 it's just like you guys towing. The oil residue had soaked into the rubber enough to make it swell. Cleaning it and reinstalling it wasn't the easiest. The next day I had the local Ford dealer deliver one. They didn't have one in stock so they pulled one off of a truck in the shop. That happend around 9,000 miles. I'm at 22,5 now and no problems.

 

Here is your answer... from Ford Motor Co.

Intercooler Hose Blow-Off:
If one of the hot side intercooler hoses blow off it will cause the truck to exhibit a low power/low boost condition. To service, replace the hot side intercooler pipe/hose assembly. Clean the hose mating surfaces to ensure the hoses will stay in place. SEat the hoeses completely onto their mounting surfaces before tightening the clamps to 9 ft/lbs. Test drive the truck while monitoring the boost pressures, which should be 22-25 PSI. An overboost condition will cause the hose to blow off. Broadcast Message 1099.
Single alternator trucks: 4C3Z-6C646-BA
Dual alternator trucks: 4C3Z-6C646-CA.


Good luck,

Jeff

 

O-boy I was close............but............not at 9ft, I know, I know, you are always supposed to follow torque specks.......albeit important, with this one make it tight.

Jeff you good, always finding these things.

 

Okay so the oil residue is normal and what I've done up to this point is pretty much the same fix as Ford. I also used brake cleaner on both ends to clean them up as much as possible then reseated it and tightened it as much as possible. I guess in the future I'll just keep a can of brake cleaner, a towel and flat head with me.

Bill

 

My experience is very much real world I live at 6k altitude and pull through and in the Rocky mountains, it will fix it if you do not go with their torque, go high on it and your fine. I do however suggest let the thing cool over night and do all four connections.

 

what do you'alls clamps look like? I have an 06/03 motor and it has a strange (to me ) looking clamp with a heavy spring and a nut on it; gold in color.

 

That is it.......right color too.

 

better tighten mine

 

Actually, we need to have an FTESB
That is a Ford Truck Enthusiastic Service Bulletin, yes I wrote enthusiastic…everyone clean and tighten all four clamps…………FTESB-0001

We are enthusiastically working to keep our trucks running!

 

I also carry a small tool box with a collection of "must have" to get my butt out of trouble when off in the brush hunting or fishing.

 

Same here, only difference between my PSD kit and my old Z-71 kit is the 6MM allen wrench in place of the spare frame mounted fuel filter and brake cleaner for the hoses instead a ball peen hammer to beat the starter with to make the solenoid engage when muddy.

 

Beat the starter....we don't have to to do that on the 6.0..yet