Intercooler Duct
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Senior User
Joined: May 2002
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From: Garden Grove USA
Intercooler Duct
These are known to blow off during heavy towing, as mine did, and the dealer replaced the entire duct from the turbo. Is this a redesigned part? Is anyone having problems with the new duct or does this fix the problem? 
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Joined: Apr 2004
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From: Wickenburg, AZ
I've never had one blow off, but I did get it to blow oil out of that duct. I assume you mean the plastic tube from the intercooler to the aluminum air intake on the engine? Mine slid back about 1/4", but never blew off. That was with a combined weight of 18000 lbs. I've got an '04 CC XLT FX4.
Anyway, when I rolled into town I tore it all down, scrubbed the duct, and made sure those clamps were tight. I haven't had any problems since, but I'm doing another tow that should be around 16000 GCW in a week. I'll post my outcomes when I roll into cowboyland again.
Anyway, when I rolled into town I tore it all down, scrubbed the duct, and made sure those clamps were tight. I haven't had any problems since, but I'm doing another tow that should be around 16000 GCW in a week. I'll post my outcomes when I roll into cowboyland again.
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From: 3rd Rock
Originally Posted by dpoelstra
These are known to blow off during heavy towing, as mine did, and the dealer replaced the entire duct from the turbo. Is this a redesigned part? Is anyone having problems with the new duct or does this fix the problem?
Clean all parts with Brake Parts Cleaner, leaves no residue.
I tighten a bit more than the way it cam from the factory, never had a problem sense...........did it twice before I figured out to clean very good.
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From: Garden Grove USA
I did the cleaning thing, but it blew off again. Took it to the dealer and there was a service bulletin to replace the entire duct assembly with a new part number.
I am concerned about it blowing off again. The dealer replaced the entire assembly, the hoses, the clamps and the duct itself. Someone must know what the changes are to this, and if this in fact fixes the problem.
I am concerned about it blowing off again. The dealer replaced the entire assembly, the hoses, the clamps and the duct itself. Someone must know what the changes are to this, and if this in fact fixes the problem.
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From: Dallas
Originally Posted by dpoelstra
I did the cleaning thing, but it blew off again. Took it to the dealer and there was a service bulletin to replace the entire duct assembly with a new part number.
I am concerned about it blowing off again. The dealer replaced the entire assembly, the hoses, the clamps and the duct itself. Someone must know what the changes are to this, and if this in fact fixes the problem.
I am concerned about it blowing off again. The dealer replaced the entire assembly, the hoses, the clamps and the duct itself. Someone must know what the changes are to this, and if this in fact fixes the problem.
This makes it just tacky enough it won't slide but still comes apart easily. By the way, don't tighten past full compression on the bolt springs, you can crush the tube.
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From: Garden Grove USA
BUT THERE IS S ERVICE BULLETIN TO REPLACE THE ENTIRE DUCT SYSTEM...
I just want to know if this fixes the problem. There was obviously a design issue if they redesigned the part. I have an entirely new duct system, that if I understand it correctly, has a different part number than the original.
I don't want to have to clean the thing, and then have it blow off on a 1600 mile tow, then have to clean it along side the freeway.
Everyone is telling me how to fix it when the proper thing to do is have the dealer replace the thing, not continually clean it.
I want to know if the replacement if the fix, or not?
I just want to know if this fixes the problem. There was obviously a design issue if they redesigned the part. I have an entirely new duct system, that if I understand it correctly, has a different part number than the original.
I don't want to have to clean the thing, and then have it blow off on a 1600 mile tow, then have to clean it along side the freeway.
Everyone is telling me how to fix it when the proper thing to do is have the dealer replace the thing, not continually clean it.
I want to know if the replacement if the fix, or not?
Last edited by dpoelstra; Jun 20, 2004 at 02:46 PM.
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From: Alabama
I just had a hose blow off the turbo side of the intercooler. Thanks to this forum I immediately knew what had happened. It makes quite a boom and a LOT of smoke! I haven't seen the new design yet (national backorder), but my dealer tells me the retainer grooves in the tubes are deeper and the mating surfaces of the hoses are redesigned to fit them. He says none he has replaced have come back yet. The old hoses are also known to split. I keep a roll of 2" fiberglass tape in my truck just in case. It's a slow go towing without boost.
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From: Hendersonville, NC
Originally Posted by dpoelstra
BUT THERE IS S ERVICE BULLETIN TO REPLACE THE ENTIRE DUCT SYSTEM...
I just want to know if this fixes the problem. There was obviously a design issue if they redesigned the part. I have an entirely new duct system, that if I understand it correctly, has a different part number than the original.
I don't want to have to clean the thing, and then have it blow off on a 1600 mile tow, then have to clean it along side the freeway.
Everyone is telling me how to fix it when the proper thing to do is have the dealer replace the thing, not continually clean it.
I want to know if the replacement if the fix, or not?
I just want to know if this fixes the problem. There was obviously a design issue if they redesigned the part. I have an entirely new duct system, that if I understand it correctly, has a different part number than the original.
I don't want to have to clean the thing, and then have it blow off on a 1600 mile tow, then have to clean it along side the freeway.
Everyone is telling me how to fix it when the proper thing to do is have the dealer replace the thing, not continually clean it.
I want to know if the replacement if the fix, or not?
) have a build date of 01/04...Just curious if mine already has the updated tubes, or if i need them. I guess, though, if mine was gonna blow a boost tube, it would have already done so. 
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From: Garden Grove USA
My original 03 had insulation on it, my neighbor's 04 had no insulation, and my new one looks just like his, with no insulation. 
Thanks for the info gonnasellit! I heard they were on backorder too, but mine was here overnight.
Thanks for the info gonnasellit! I heard they were on backorder too, but mine was here overnight.
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From: 3rd Rock
Originally Posted by dpoelstra
BUT THERE IS S ERVICE BULLETIN TO REPLACE THE ENTIRE DUCT SYSTEM...
I just want to know if this fixes the problem. There was obviously a design issue if they redesigned the part. I have an entirely new duct system, that if I understand it correctly, has a different part number than the original.
I don't want to have to clean the thing, and then have it blow off on a 1600 mile tow, then have to clean it along side the freeway.
Everyone is telling me how to fix it when the proper thing to do is have the dealer replace the thing, not continually clean it.
I want to know if the replacement if the fix, or not?
I just want to know if this fixes the problem. There was obviously a design issue if they redesigned the part. I have an entirely new duct system, that if I understand it correctly, has a different part number than the original.
I don't want to have to clean the thing, and then have it blow off on a 1600 mile tow, then have to clean it along side the freeway.
Everyone is telling me how to fix it when the proper thing to do is have the dealer replace the thing, not continually clean it.
I want to know if the replacement if the fix, or not?
I have done it in the middle of nowhere at 3AM beside the road
fun fun fun
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Joined: Jan 2003
Posts: 161,999
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From: 3rd Rock
ZERO power, I blew the end off of the intercooler and had to drive 34 miles into town towing real big trailer..........ug.........IMO the only way you can do it, (drive it in that is) if you have an EGT gauge, because it will sky rocket.
Must be very careful.
Now when you blow the tube off just stop and fix it, that is why I suggest to do it in the garage first time, clean retighten and all. Then hopefully you will never have to do it. But if you do..............been there done that
Must be very careful.
Now when you blow the tube off just stop and fix it, that is why I suggest to do it in the garage first time, clean retighten and all. Then hopefully you will never have to do it. But if you do..............been there done that
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From: Garden Grove USA
Cleaning it is all fine and dandy, but the bottom line is there is a design problem which makes the thing blow off. Mine blew off in the Arizona desert on the way to the Grand Canyon towing the fifth wheel. I fixed it on the road, then took it apart at the campground. Cleaned it thourougly. Got it real tight. Blew off again 300 miles later.
Quit the cleaning and tightening. Take it to the dealer and have-em change it! I am just hoping that the new duct assembly fixes the problem. I know that there have been a ton of these blow off, but I haven't heard how the new assembly hold up. The dealer says that fixes it, but you never know.
Quit the cleaning and tightening. Take it to the dealer and have-em change it! I am just hoping that the new duct assembly fixes the problem. I know that there have been a ton of these blow off, but I haven't heard how the new assembly hold up. The dealer says that fixes it, but you never know.