Intercooler hose clamp
Cross-Country
Joined: Nov 2004
Posts: 73
Likes: 0
From: Maryland
My truck is at 52,000 miles, it's been 25 to 35,000 miles since I had fixed my tube with the sandpaper, grooves and blue RTV gasket maker. Hadn't had a problem with it again just till the other day. It broke the seal I had created.
It made me think of this post where I had stated that I hadn't had a problem with it since.
I heard a noise that sounded like wind around a leaky house window in a wind storm (when under excelleration only).
The blue gasket maker kept most of the pipe on still. But it was so oil sooked for so long it broke the seal finally.
I took the tube completely off, cleaned it with paint thinner, applied grey gasket maker and it's been good again so far.
It made me think of this post where I had stated that I hadn't had a problem with it since.
I heard a noise that sounded like wind around a leaky house window in a wind storm (when under excelleration only).
The blue gasket maker kept most of the pipe on still. But it was so oil sooked for so long it broke the seal finally.
I took the tube completely off, cleaned it with paint thinner, applied grey gasket maker and it's been good again so far.
Senior User
Joined: Jul 2006
Posts: 344
Likes: 0
From: Colorado Springs, CO
I bought an extra clamp and sandpapered the hose and the intake lightly. I haven't done the gasket material yet. I did disconnect the EGR also, so maybe the lower boost will help keep it on there. I know the turbo whine is a lot less. I saw from the Oasis report that it has happened to this truck 5 times in the past, 6 counting me. How bad is that design? LOL. Just hope I make it to the park and back tomorrow.
Logistics Pro
Joined: Dec 2004
Posts: 3,541
Likes: 5
From: Weatherford Texas.
Originally Posted by thexman
What do the 05 tubes look like? Any problems with them, I hope not.
Senior User
Joined: Jul 2006
Posts: 344
Likes: 0
From: Colorado Springs, CO
Originally Posted by wb6anp
the '05 and '06 tubes are black plastic, Had the turbo to intercooler blue hose blow off my '05 while pulling TT up a hill, the hose came off at the turbo. But it came off also because the clamp broke through the straple holes in the clamp I'am now watching my '06 it has the same clamp. (picture of clamp in my gallery)
Last edited by chili7; Jul 24, 2006 at 01:06 AM.
Senior User
Joined: Jul 2006
Posts: 344
Likes: 0
From: Colorado Springs, CO
It did it AGAIN. Back from the dealer two days. I took 3 days vacation to take the 5th and family up to Rocky Mtn. NP and BOOM. 20 miles from home. We are back, I fixed it on the side of I-25 at 3PM. There it sits in the shop now, no ETA. Kids were crying, fun stuff all around. The beauty of it is they want to put an addon computer to capture the data when it blows again. NO replacing the turbo until Detroit says replace it, even though they know it's a boost issue. I made the salesguy and the service manager understand I wasn't happy, but there's no point in pissing them off. I'm in customer service myself and I get it. I just want it fixed. Per the Oasis, there is 4 for the last guy and #2 for me in two weeks with a tow. If I wanted something I can't tow with, I would have bought it.
Oh yeah, the EGR was disconnected when it blew. I was hoping that the boost would reduce enough to prevent another hose blow out, but no luck. I was also on nearly level ground at about 2k RPM. Some thing is just not right.
Oh yeah, the EGR was disconnected when it blew. I was hoping that the boost would reduce enough to prevent another hose blow out, but no luck. I was also on nearly level ground at about 2k RPM. Some thing is just not right.
Last edited by chili7; Jul 24, 2006 at 10:45 PM.
Postmaster
Joined: Dec 2003
Posts: 3,359
Likes: 0
From: Dallas
Mine comes once around once a year if I don't check the tightness every few months. I just smile and put it back on with the sandpaper drill I think I invented in jan or feb of 04. Every time it happens I think wow, because I know it has to be making well over 30 pounds boost to blow it off!
Senior User
Joined: Jul 2006
Posts: 344
Likes: 0
From: Colorado Springs, CO
I hear ya, but is fixing the hose the solution for this problem? Why are you/me getting that kind of boost if the turbo is working correctly? That's my question. The other side of this is if it's a known issue, why is Ford so slow to make the necessary fixes, but that's another thread prolly. They have one more try. Three and yer out. I'm not trying to reinvent the world here, but if I can't trust the truck with my family inside, that's a problem. I love this truck and that may be a bad thing.
Last edited by chili7; Jul 25, 2006 at 01:57 AM.
Post Fiend
Joined: Apr 2004
Posts: 19,098
Likes: 8
From: Great State of Texas
Originally Posted by Choctaw Bob
Mine comes once around once a year if I don't check the tightness every few months. I just smile and put it back on with the sandpaper drill I think I invented in jan or feb of 04. Every time it happens I think wow, because I know it has to be making well over 30 pounds boost to blow it off!
Back in the 6.0 business?
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...I got him back though....I accepted. 
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Super Moderator
Joined: Jul 2004
Posts: 21,113
Likes: 3,939
From: Ohio
Originally Posted by Choctaw Bob
Mine comes once around once a year if I don't check the tightness every few months. I just smile and put it back on with the sandpaper drill I think I invented in jan or feb of 04. Every time it happens I think wow, because I know it has to be making well over 30 pounds boost to blow it off!
Both of my pipes are metal and I have never had a problem. Clean, borrow the wifes hair spray, torq to spec. I see Ford uses metal then plastic, so I would think the plastic pipes would be more of a problem.
Senior User
Joined: Apr 2004
Posts: 471
Likes: 0
From: Laporte , Indiana
Thank you for acccepting KW. We need somebody in charge of this crazy group. Crazy , but more knowledge than any dearler than I have dealt with. Anyway, My 04 blew off 12 times. The first 5 or 6 was because I reinstalled incorrectly. The rest are from over boost. My dealer kept saying everhting is within specs. I was frustrated because if everything was within spec then why am I still blowing off this tube. Did I mention FRUSTRATING. It got to a point were I did not trust the truck anymore. 2 vacations in a row was disrupted because of this. I went to my dealer parked the truck in front of there dealership and said I am not leaving until they do one of two things. Put a new turbo on this truck or give me one heck of a deal on an 06. I am now driving a new 06 with zero problems.
Guess what happened to my 04. A freinds calls me up and says he bought an 04 just like mine. You guessed it. He bought my truck off the used lot. And yes the truck still had the issue with the turbo. I went with him to the dealer in the truck. The look on the face of the delaer manager was priceless. We did the same thing Fix or new. They ordered the new turbo and fixed it this time. Truck has not had a problem since.
Guess what happened to my 04. A freinds calls me up and says he bought an 04 just like mine. You guessed it. He bought my truck off the used lot. And yes the truck still had the issue with the turbo. I went with him to the dealer in the truck. The look on the face of the delaer manager was priceless. We did the same thing Fix or new. They ordered the new turbo and fixed it this time. Truck has not had a problem since.
Elder User
Joined: Mar 2004
Posts: 853
Likes: 0
From: Oregon
Widcat: Was the new Turbo one with the special cut vanes? I hear that this will help and mine is in the shop now for the same thing. If they just try to use the old parts I'm going to fly off the handle big time. I don't think they realize that they are dealing with peoples lives here. I nearly got in an accident the three previous time while pulling a load and a hill, when it goes it looses all power and the truck wont even get out of its own way. Ford is real close to ticking off a 250lb mad man!!!!!!!
Senior User
Joined: Jul 2006
Posts: 344
Likes: 0
From: Colorado Springs, CO
wildcat421, were' going to have that conversation in about an hour. Thanks.
And Enomra, they absolutely are playing with people lives. It was dangerous sitting on the side of I-25 with traffic going by at 75-90 mph repairing that tube. There is only one sure way to make me crazy and that is to put my family in harms way.
And Enomra, they absolutely are playing with people lives. It was dangerous sitting on the side of I-25 with traffic going by at 75-90 mph repairing that tube. There is only one sure way to make me crazy and that is to put my family in harms way.
Senior User
Joined: May 2006
Posts: 410
Likes: 0
I bought the Banks intercooler for my 06 before my truck had 2000 miles on it. The banks boost tube blew off for me 5 times on one trip. Same hot nasty roadside BS and crying baby in the car with No AC on the side of the 105 degree road. After getting home, Called Banks and they redesigned the boost tube, coupler and clamp from the original. The original used the stock clamp to the turbo(the one I had problems with). They have since redesigned the tube, coupler and use clamps that don't have any springs on them. They are just beefy clamps. The new designed has been working great. To insure that the tube physically could not come off, I safety wired the boost tube to the alternater bracket. Been fine so far. I personally think the design of the boost tube just flopping in the breeze only to be supported by one 2 1/2" hoseclamp with a VERY small lip on the turbo flange is bad from the start. As far as boost goes, I have the Banks PDA monitoring boost, and under the heaviest of loads I see 34 psi. The dummy gauge on the dash never goes over 25 psi. So, if anyones dummy gauge reads high, then who knows what psi is actually being reached.