Intercooler Duct
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Senior User
Joined: May 2002
Posts: 484
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From: Garden Grove USA
Yeah, stock as a clock. Left me by the freeway 3 times on a 1600 mile tow. Twice after I took it all apart and cleaned it at the campground. I thought I had it then. I actually put a cheap radiator hose clamp on with it to get me home. 
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Joined: Dec 2003
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From: Dallas
Mine blew of 3 times today on the second leg of a 400 mile trip. i will call my dealer tomorrow to see if there is a service bulliten.
I'm sure I can fix it myself. It actually will take me 15 minutes to fix it vs the 3 or 4 hours it will take to take it to the dealer and wait on it to be fixed.
The problem on mine is the flange on the turbo is not large enough to hold the hose.
I'm sure I can fix it myself. It actually will take me 15 minutes to fix it vs the 3 or 4 hours it will take to take it to the dealer and wait on it to be fixed.
The problem on mine is the flange on the turbo is not large enough to hold the hose.
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Joined: Mar 2004
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From: Mountains of NE CA
I posted this in "intercooler hose clamp" and thought belonged here as well.
Just curious, have most of these intercooler tube blow outs happened on the intercooler to intake manifold side or vice/versa? and were they plastic tubes or aluminum?
I noticed when comparing my dad's 04 f350 DRW 6.0 with my 04 f350 SRW 6.0 that on his truck both intercooler tubes were what appear to aluminum tubing. His tubes are connected at each end with blue hose like material and spring load clamps.
My truck has aluminum tubing from turbo to intercooler with blue hose material and spring loaded clamps and plastic tubing (like Matt1751 photo) from intercooler to intake manifold with hose type clamps (like Matt1751 photo). It would appear the hose clamps and plastic hose would be more likely to slip or blow off. On a side note: my tube from turbo to intercooler is squished almost in half to give extra clearance for dual alternators while my dad has single alt and constant diameter tubing. This does not make me happy as the restricted flow must hurt performance.
Sorry for rambling, just putting out some food for thought.
Just curious, have most of these intercooler tube blow outs happened on the intercooler to intake manifold side or vice/versa? and were they plastic tubes or aluminum?
I noticed when comparing my dad's 04 f350 DRW 6.0 with my 04 f350 SRW 6.0 that on his truck both intercooler tubes were what appear to aluminum tubing. His tubes are connected at each end with blue hose like material and spring load clamps.
My truck has aluminum tubing from turbo to intercooler with blue hose material and spring loaded clamps and plastic tubing (like Matt1751 photo) from intercooler to intake manifold with hose type clamps (like Matt1751 photo). It would appear the hose clamps and plastic hose would be more likely to slip or blow off. On a side note: my tube from turbo to intercooler is squished almost in half to give extra clearance for dual alternators while my dad has single alt and constant diameter tubing. This does not make me happy as the restricted flow must hurt performance.
Sorry for rambling, just putting out some food for thought.
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Joined: May 2002
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From: Garden Grove USA
All aluminuminimuminimumin 
The older ones are insulated, the new ones are not. Mine blew out on the radiator connection, but many have had them blow out on the top, with a few dents in the hood.
Anyone who has to clean it to keep it from blowing off needs to have the dealer replace the entire duct assembly. The originals on the 03's are just made wrong, so replace it. I can tell that the new one fits more securely than my old one did. I think the flange is bigger to hold the hose on. It seems that it is a matter of time before it is a real problem, and since it is not a recall, it may not be covered under waranty. Do it now is my advice.
The older ones are insulated, the new ones are not. Mine blew out on the radiator connection, but many have had them blow out on the top, with a few dents in the hood.
Anyone who has to clean it to keep it from blowing off needs to have the dealer replace the entire duct assembly. The originals on the 03's are just made wrong, so replace it. I can tell that the new one fits more securely than my old one did. I think the flange is bigger to hold the hose on. It seems that it is a matter of time before it is a real problem, and since it is not a recall, it may not be covered under waranty. Do it now is my advice.
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Joined: Feb 2003
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tube repair
If you take the tube to a muffler shop and have them expand the end of the tube a little it will stay on. My tube was actually tapered in some and when trying to tighten the clamp the hose would be forced off the tube.
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Joined: May 2004
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From: stoneboro, pa
ok, does anyone know what the TSB is on this "tube and boot"? who has had it done? go look at ur warranty paper and post the #, please.
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From: Garden Grove USA
Originally Posted by flyboy5111
If you take the tube to a muffler shop and have them expand the end of the tube a little it will stay on. My tube was actually tapered in some and when trying to tighten the clamp the hose would be forced off the tube.
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From: 3rd Rock
Originally Posted by flyboy5111
If you take the tube to a muffler shop and have them expand the end of the tube a little it will stay on. My tube was actually tapered in some and when trying to tighten the clamp the hose would be forced off the tube.
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Joined: Apr 2004
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My 2004 has metal tubing with blues hoses and clamps whith springs are these the new ones? I'm planning on doing a 600 mile round trip next and hate for this to happen. Then I would have to hear the following from the wife, "That's what you get for buying a Ford".
A brief backround as to why she says this. February 2004 purchased a zero miles f150 lariat with 5.4 liter engine, arizona beige with black leather, loaded except for the 4x4. In 1 1/2 months spent 10 days at dealer, had 4 tires replaced, rack and pinion and a/c control unit. None of these things that where changed fixed the numerous problems that it had. So off course my wife instead of standing by me, all she said was the above quote wich I rather DIE than repeat! Well last month got rid of the truck with 3,300 miles and gor the f250 6.0.
I have 1,200 miles on it now and have a couple of problems that I need the dealer to address, and I'm tempted to have them change the oil to free-load on the 1 free change, but I think will both [the truck and I] be better off if I do it.
Happy motoring.
A brief backround as to why she says this. February 2004 purchased a zero miles f150 lariat with 5.4 liter engine, arizona beige with black leather, loaded except for the 4x4. In 1 1/2 months spent 10 days at dealer, had 4 tires replaced, rack and pinion and a/c control unit. None of these things that where changed fixed the numerous problems that it had. So off course my wife instead of standing by me, all she said was the above quote wich I rather DIE than repeat! Well last month got rid of the truck with 3,300 miles and gor the f250 6.0.
I have 1,200 miles on it now and have a couple of problems that I need the dealer to address, and I'm tempted to have them change the oil to free-load on the 1 free change, but I think will both [the truck and I] be better off if I do it.
Happy motoring.
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Joined: Feb 2003
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I did this several months ago, before any info about new tube. Sometimes it is easier to repair the little things yourself. My dealer is 35 miles away and I would have had to make two trips to get the job done, a little time and a thanks to the muffler shop is all it took.
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Joined: Jun 2004
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From: Breaux Bridge,La.
Just had my new 04-F250 w/365 milesin to replace the injector driver module and I notice on the bottom of the work order/invoice that they replaced the following:
6646at duct-engine charge air cooler -(6c640/6c646)-L
Is this the same thing that is being discussed above? Thanks Wes
6646at duct-engine charge air cooler -(6c640/6c646)-L
Is this the same thing that is being discussed above? Thanks Wes
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wsnead56
1973 - 1979 F-100 & Larger F-Series Trucks
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Mar 18, 2012 08:14 PM
