Intercooler hose clamp
New User
Joined: Sep 2006
Posts: 9
Likes: 0
KW5413,
Not a problem, I appreciate all the advice and counsel I can get.
I ordered the truck to my specifications and took delivery in mid June 2004. The red sticker on the passenger side valve cover says 2004 engine. I believe that they reflashed the chip back in November of 2005 when the turbo was replaced. Are there more recent software updates?
I have the original metal pipe between the two blue plastic couplers on the hot side of the turbo and I understand that the replacement is plastic - not sure if the plastic is an upgrade or not?
Not a problem, I appreciate all the advice and counsel I can get.
I ordered the truck to my specifications and took delivery in mid June 2004. The red sticker on the passenger side valve cover says 2004 engine. I believe that they reflashed the chip back in November of 2005 when the turbo was replaced. Are there more recent software updates?
I have the original metal pipe between the two blue plastic couplers on the hot side of the turbo and I understand that the replacement is plastic - not sure if the plastic is an upgrade or not?
Last edited by 3xldawg; Sep 20, 2006 at 11:48 AM.
Post Fiend
Joined: Apr 2004
Posts: 19,098
Likes: 8
From: Great State of Texas
The metal pipe is best, IMO.
Well, you have likely already read the best fixes for the blown turbo hoses. As a review this is what I would do:
And good luck.
Well, you have likely already read the best fixes for the blown turbo hoses. As a review this is what I would do:
- With a course sand paper rough up the inside diameter of the Blue Hoses deep enough to cover the outside diameter of the metal tube.
- Do the same with the O.D. of the metal tube.
- Clean all contact surfaces with Brake Kleen
- In some cases I have read that some folks have used a high temperature resistance silicone adhesive applied to both contact surfaces. Can't confirm the results.
- Some have even drilled holes thru the clamp, sleeve, and pipe. Then used self tapping stainless sheet metal screws for a more permanent solution. I would caution that if you do this, remove the hoses after drilling and make sure there are no metal shavings. Then replace. Note: aligning all the holes may prove difficult so patience and planning is paramount to success.
- Tighten clamps (my torque spec involves tightening her down 'til it feels just right then add an extra little twist).
And good luck.
New User
Joined: Sep 2006
Posts: 9
Likes: 0
kw5413,
Thanks - I now have gloves, sandpaper, spare blue turbo tubes, spare clamps and brake kleen on board at all times now. After you have done the turbo pipe reinsntall a few times it goes pretty fast.
Now in trying to track down the cause of my pipe blow off, in both main cases it only happened at high altitude +/- 6000 ft above sea level. I am wonderinng if boost can ramp up past the pressure threshold of the pipe & clamps if the EPB sensor is giving the computer the wrong barometric pressure? I will try to get the local dealer to check/replace the EPB and VGT sensor units.
Thanks - I now have gloves, sandpaper, spare blue turbo tubes, spare clamps and brake kleen on board at all times now. After you have done the turbo pipe reinsntall a few times it goes pretty fast.
Now in trying to track down the cause of my pipe blow off, in both main cases it only happened at high altitude +/- 6000 ft above sea level. I am wonderinng if boost can ramp up past the pressure threshold of the pipe & clamps if the EPB sensor is giving the computer the wrong barometric pressure? I will try to get the local dealer to check/replace the EPB and VGT sensor units.
Postmaster
Joined: Jun 2004
Posts: 2,646
Likes: 1
From: Milky Way Galaxy
Go get the new, upgraded blue hoses and clamps from the dealer. I had the same problem. Even had them replaced in '05, with supposed "upgraded" ones, but it still blew-off. Tried all the tricks (minus drilling) and kept blowing the tube off. I finally went to Pepboys and got some thick aluminum clamps and they worked. Well, I just recently (3 months ago) had my truck in for another oil leak, which by the way my trucks now been oil leak free for 3k miles (after 2 yrs., 15 visits and 9 leaks), thanks to a new, well trained, tech, but anyway. While I was in there for the oil leak the service adviser wrote down a laundry list of known problems with 6.0's. Mine wasn't necessarily having these problems, the SA just wanted them checked. I got the truck back with the new hose and clamps, and the tech was even nice enough to remove and return my aftermarket clamps, and not only have I not had them blow-off again, but there's also absolutely zero oil seepage through the new ones. So whatever they did with this newest version of the hose and clamp, it's working.
Senior User
Joined: Jul 2006
Posts: 344
Likes: 0
From: Colorado Springs, CO
My dealer finally put a screw through the upper hose clamp into the turbo manifold after sanding, scraping, cleaning, etc. Also had the EGR and EBP sensor replaced, if that helped. The screw held it during my last trip, but the turbo was still winding up and down with no rhyme or reason, on a hill or flat. They fixed the problem but not the cause. After 3 blow offs (and 3 for the previous owner), they said the turbo was still within spec and they refused to replace or service it. This was after the regional tech did a full analysis. Since I only owned the truck for two months, the agreed to let me trade it for full value on a an 05. That's all in another thread I posted. The 04 had all recalls and the latest flash. I get to finally do a test pull on my 5'ver this weekend. All my toes and fingers are crossed.
Last edited by chili7; Sep 21, 2006 at 10:48 PM.
New User
Joined: Sep 2006
Posts: 9
Likes: 0
I have the new thicker blue pipe (angled upper one) and the old clamp and it held fine on a 1000 mile trip hauling a car trailer with a car - highest altitude was 4150 ft above sea level. I was careful not to romp on it - tried to keep it no higher than 2300 rpms and steady.
Just in case I am taking it to the dealer in the morning to check the EPB sensor before I try going over the sierras.
So maybe as EnviroCon says the new pipe is a good fix. So far So Good.
Just in case I am taking it to the dealer in the morning to check the EPB sensor before I try going over the sierras.
So maybe as EnviroCon says the new pipe is a good fix. So far So Good.
Freshman User
Joined: Jun 2005
Posts: 36
Likes: 0
part numbers for the updated parts?
bers
Do you have the part numbers for the updated parts they put on your truvk? That would help the rest of us get the new parts ourselves....
Originally Posted by EnviroCon
Go get the new, upgraded blue hoses and clamps from the dealer. I had the same problem. Even had them replaced in '05, with supposed "upgraded" ones, but it still blew-off. Tried all the tricks (minus drilling) and kept blowing the tube off. I finally went to Pepboys and got some thick aluminum clamps and they worked. Well, I just recently (3 months ago) had my truck in for another oil leak, which by the way my trucks now been oil leak free for 3k miles (after 2 yrs., 15 visits and 9 leaks), thanks to a new, well trained, tech, but anyway. While I was in there for the oil leak the service adviser wrote down a laundry list of known problems with 6.0's. Mine wasn't necessarily having these problems, the SA just wanted them checked. I got the truck back with the new hose and clamps, and the tech was even nice enough to remove and return my aftermarket clamps, and not only have I not had them blow-off again, but there's also absolutely zero oil seepage through the new ones. So whatever they did with this newest version of the hose and clamp, it's working.
FTE Stories
Ford Trucks for Ford Truck Enthusiasts
2027 Ford Super Duty Buyer's Guide (Every Model, Engine, & Package)
Brett Foote
Top 10 Ford Truck Tragedies
Joe Kucinski
AEV FXL Super Duty - the Super Duty Raptor Ford Doesn't Make
Brett Foote
Lobo Vs Lobo: Proof the F-150 Lobo Should Be Even Lower!
Michael S. Palmer
Ford's 2001 Explorer Sportsman Concept Looks For a New Home
Verdad Gallardo
10 Best Ford Truck Engines We Miss the Most!
Joe Kucinski
2026 Shelby F-150 Off-Road: Better Than a Raptor R?
Brett Foote
2027 Super Duty Carhartt Package First Look: 12 Things You NEED to Know!
Michael S. Palmer
10 Most Surprising 2026 Ford Truck Features!
Joe Kucinski
New User
Joined: Sep 2006
Posts: 9
Likes: 0
These are the parts I picked up for my 2004 (engine tag says it is a 2004 motor) 6.0;
Upper Blue hose :5C3Z-6C640-AA
Upper Clamps (two req'd) : 6C2Z-6K786-AA
Lower Blue Hose :6C3Z-6C640-B
Lower Clamps (two req'd) : 6C3Z-6K786-CA
The new upper hose it definately thicker and stiffer than the original one that came with the truck.
The new Lower hose has two stainless wire bands around it.
Upper Blue hose :5C3Z-6C640-AA
Upper Clamps (two req'd) : 6C2Z-6K786-AA
Lower Blue Hose :6C3Z-6C640-B
Lower Clamps (two req'd) : 6C3Z-6K786-CA
The new upper hose it definately thicker and stiffer than the original one that came with the truck.
The new Lower hose has two stainless wire bands around it.
Postmaster
Joined: Jun 2004
Posts: 2,646
Likes: 1
From: Milky Way Galaxy
Originally Posted by ebolavirs
Do you have the part numbers for the updated parts they put on your truvk? That would help the rest of us get the new parts ourselves....
Originally Posted by 3xldawg
These are the parts I picked up for my 2004 (engine tag says it is a 2004 motor) 6.0;
Upper Blue hose :5C3Z-6C640-AA
Upper Clamps (two req'd) : 6C2Z-6K786-AA
Upper Blue hose :5C3Z-6C640-AA
Upper Clamps (two req'd) : 6C2Z-6K786-AA
Hotshot
Joined: Dec 2003
Posts: 15,368
Likes: 121
From: Stuttgart, Ar
Since I was lazy and didn't go through the whole 2 years of thread........Is it just my blue tubes that have an internal groove that fits onto the ridge of the metal pipe? Seems that once I get the blue tube locked onto that ridge on the pipe and get the clamp positioned correctly over it I never have any problem and I pull 36psi boost at WOT and hold 30psi steady and (knock on wood) I've never had any problem.
New User
Joined: Sep 2006
Posts: 9
Likes: 0
The blue tubes (both old and new) have the grooves etc. and correct groove alignment and cleaned surfaces are critical for the clamps to hold the tubes to the turbo and connector pipe. The mystery for me has been that my pipes continued to blow off after installation/reinstalltion by four (4) separate Ford diesel techs from Idaho to California who all had to know about the critical alignment and clean connections - the difference so far (the last month) has been the new blue pipe which is thicker and stiffer than the old one seems to be holding. This is after repeated code dumps by Ford techs and checkups and a turbo replacement by certified ford diesel techs.
Just had everything re-checked today at my local Ford dealer and they say it all looks good - so I'm going Elk hunting and maybe I should knock on wood.
Just had everything re-checked today at my local Ford dealer and they say it all looks good - so I'm going Elk hunting and maybe I should knock on wood.
Senior User
Joined: Feb 2005
Posts: 347
Likes: 0
OK, I was lazy too, should all the clamps\fittings be cleaned and reinstalled? I had 1 blow off and asked the dealer to clean and check all and they said it all looked good. Even though they didn't clean all of the clamps.
Here I was trying to be a nice guy and save Ford some money by not having to repair my hood again. Silly me.
Here I was trying to be a nice guy and save Ford some money by not having to repair my hood again. Silly me.
Senior User
Joined: Feb 2005
Posts: 347
Likes: 0
Originally Posted by 3xldawg
See Kw5413's list of fixes about 10 comments back - I think that all contact surfaces have to be clean to have any hope of holding.