Catastrophic Intercooler Failure
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Catastrophic Intercooler Failure
I have an '03 F-350 with the 6.0PSD. The other day, while pulling my 30' 5th wheel travel trailer (10000 lbs), I heard a loud "BOOM", like a canon going off under the hood. After that, I could not go over 40MPH. I limped in to the nearest dealer and was told I blew up my intercooler. Now, I have heard of hoses blowing off, but have never heard of this. I have talked to some friends at Ford Truck Engineering, who have never heard of this.
The service adviser was trying to blame it on my Banks "CAT-Back" Monster Exhaust and wasn't going to warrantee it. Being an engineer, I managed to convince Ford the the SA was il-informed and they covered it.
Has anyone ever heard of this hapening?
The service adviser was trying to blame it on my Banks "CAT-Back" Monster Exhaust and wasn't going to warrantee it. Being an engineer, I managed to convince Ford the the SA was il-informed and they covered it.
Has anyone ever heard of this hapening?
Former Vendor
Joined: Mar 2004
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From: Hendersonville, NC
I have never heard of this problem before. IMO it can't be blamed to an "overboost problem" because there are many, many, many other things that would have went first. The only idea that comes to mind would be a freak incident in construction of the cooler that left it with a fatal weak spot or a batch of poor metallurgical/materials in the construction.
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Joined: Mar 2004
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From: Oregon
I have heard of this my friend at the local Ford shop has had to work on one that had a BD sys on it and he had a bad intercooler he checked the boost and it would peak at nearly 58 lbs and this caused the failure. He thinks the aluminum housing on the 7.3 may fit on these 6.0 and you may be able to replace the plastic one.
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Man, that is freaky. But I'm courious, what argument were they trying to use that it was the exhaust system that caused it? This should be good.
Actually, that is the funny part. Ater I told him I was an ME, he kind o stopped talking. I also forgot to mention that he wanted to reinstall a "factory" exhaust, that he just happend to have in stock to the tune of $750.
I took my truck and high-tailed it out of there.
Actually, that is the funny part. Ater I told him I was an ME, he kind o stopped talking. I also forgot to mention that he wanted to reinstall a "factory" exhaust, that he just happend to have in stock to the tune of $750.
I took my truck and high-tailed it out of there.
Senior User
Joined: Apr 2003
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From: Eielson AFB, AK
I'm still trying to figure out why they use plastic endtanks on these intercoolers? I mean we run higher than normal boost than a gasser does, well some gassers...I can see why Volvo uses them, only 7lbs of boost in the S40, but why in our trucks?
It would make hella more sense to use an all aluminum core with aluminum endtanks than this crappy core and plastic endtanks that are pressed on. Uber cheesy.
It would make hella more sense to use an all aluminum core with aluminum endtanks than this crappy core and plastic endtanks that are pressed on. Uber cheesy.
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From: 3rd Rock
Originally Posted by resqdawg3
I'm still trying to figure out why they use plastic endtanks on these intercoolers? I mean we run higher than normal boost than a gasser does, well some gassers...I can see why Volvo uses them, only 7lbs of boost in the S40, but why in our trucks?
It would make hella more sense to use an all aluminum core with aluminum endtanks than this crappy core and plastic endtanks that are pressed on. Uber cheesy.
It would make hella more sense to use an all aluminum core with aluminum endtanks than this crappy core and plastic endtanks that are pressed on. Uber cheesy.
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From: 3rd Rock
Originally Posted by resqdawg3
That's so bogus. Especially on a critical part like that.
Bogus it may be to you but to Ford and the their stock holders, the bottom line is big. I remember when Chevy decided not to paint the bottom half of all the Small Blocks saved them millions over time.....so....I do not agree either, however they are in business to make money….ours.
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Joined: Dec 2003
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From: Dallas
Originally Posted by FredsF250TD
Man, that is freaky. But I'm courious, what argument were they trying to use that it was the exhaust system that caused it? This should be good.
Lead Driver
Joined: Apr 2002
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From: Tampa Bay, FL USA
Correct me if I'm wrong, but a turbocharger runs off the exhaust system, right? Modify the exhaust on a modern, computerized, complicated 32-valve diesel engine, and you're changing how the turbo operates and performs, especially one with variable vanes. If the modified exhaust causes an over-boost situation, aren't you just asking for trouble? And then you expect the manufacturer to fix it, for free? The facts are this: Ford is looking to reduce warranty expense everywhere they can. The quickest, cheapest, easiest place to start is with modified vehicles. I'm not saying Ford is necessarily right, but they are in the driver's seat on this one. Moral of the story: hold off on your mods till AFTER the warranty expires.
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Joined: Dec 2003
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From: Dallas
Originally Posted by 1956MarkII
Correct me if I'm wrong, but a turbocharger runs off the exhaust system, right? Modify the exhaust on a modern, computerized, complicated 32-valve diesel engine, and you're changing how the turbo operates and performs, especially one with variable vanes. If the modified exhaust causes an over-boost situation, aren't you just asking for trouble? And then you expect the manufacturer to fix it, for free? The facts are this: Ford is looking to reduce warranty expense everywhere they can. The quickest, cheapest, easiest place to start is with modified vehicles. I'm not saying Ford is necessarily right, but they are in the driver's seat on this one. Moral of the story: hold off on your mods till AFTER the warranty expires.
My dealer modifies and puts their own badge on some of the trucks they sell. It would be very difficult for them to deny anything except the obvious.
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