2004 6.0 psd 5k miles While towing my travel trailer Saturday I was climbing a hill at aprox 55 mph in the tow/haul mode and not to bad a grade when all of a sudden I heard a loud bang and I could see the engine hood raise and settle back down. I immediately told my wife we had just blown the engine (sure sounded like it). I tried to get off to the side but had very little room and the engine was still running but very little power. I proceeded aprox. 1 block to where I could pull off, left the engine running, raised the hood and found the hose with the hose clamp on it directly behind the radiator had blown off. I put it back on, tightened the clamp and everything was fine. I went on to our camp site on the coast. Today coming home I was climbing a long grade and was under a heavy load and it happened again. (pouring down rain). Put hose back on and drove 100 miles home with no problem. This 6.0 has aprox. 5k miles on it and is an 04. I am going to go to dealer this week but does anyone have any idea what is wrong? Thanks Dick Hanford, CA

 

I had the same problem happen to me but on my '03. I was passing a car and then...."poof". I limped into a Ford dearlership and just by hearing me pull in, he identified my problem. Ford came out with a fix for it and it isn't under a TSB but some other bulletin Ford puts out. Sorry! It replaces the clamps and the tube between the intake and the turbo. I haven't had a problem since with that. Hope it gives you a start in the right direction.

 

Intercooler Hose Blow-Off:
If one of the hot side intercooler hoses blow off it will cause the truck to exhibit a low power/low boost condition. To service, replace the hot side intercooler pipe/hose assembly. Clean the hose mating surfaces to ensure the hoses will stay in place. Seat the hoeses completely onto their mounting surfaces before tightening the clamps to 9 ft/lbs. Test drive the truck while monitoring the boost pressures, which should be 22-25 PSI. An overboost condition will cause the hose to blow off. Broadcast Message 1099.
Single alternator trucks: 4C3Z-6C646-BA
Dual alternator trucks: 4C3Z-6C646-CA.
On 2004 trucks that exhibit the cold side hose/pipe blowing off at the intake manifold, this may be due to the clamp being under torqued or damaged. Clean the outside of the intake manifold inlet and the inside of the hose or pipe. Inspect the clamp, and if it is damaged, replace it (trucks built from 12-15-03 to 4-1-04, P/N 4C3Z-6F081-AA; built after 4-1-04, P/N 1C3Z-6K786-BA). Seat the hose/pipe onto the intake manifold and torque the clamp (6 ft/lbs 12-15-03 to 4-1-04; 9 ft/lbs after 4-1-04). Broadcast Message 1329.

Here's the link... http://dan.prxy.org/Truck/F-350_main...SBs_FRAME.html

 

Hey Bubba,

Ya this is due to a bad set of intercooler pipe boots. Your dealer will know all about it, Just tell them you blew your intercooler pipe off and want the new pipe and boots. It's a warranty thing and it's broadcasted so they will be able to find it. If then can't, then you really really need a new dealer because they are idiots.

Best of Luck,
Corey

Edit: well he beat me too it, but one thing I have to add is just check your hood and make sure there is no dents from it, if there is tell them to fix them.

 

It is a known problem. Here is a Ford Service Bulletin:

Intercooler Hose Blow-Off:
If one of the hot side intercooler hoses blow off it will cause the truck to exhibit a low power/low boost condition. To service, replace the hot side intercooler pipe/hose assembly. Clean the hose mating surfaces to ensure the hoses will stay in place. Seat the hoeses completely onto their mounting surfaces before tightening the clamps to 9 ft/lbs. Test drive the truck while monitoring the boost pressures, which should be 22-25 PSI. An overboost condition will cause the hose to blow off. Broadcast Message 1099.
Single alternator trucks: 4C3Z-6C646-BA
Dual alternator trucks: 4C3Z-6C646-CA.
On 2004 trucks that exhibit the cold side hose/pipe blowing off at the intake manifold, this may be due to the clamp being under torqued or damaged. Clean the outside of the intake manifold inlet and the inside of the hose or pipe. Inspect the clamp, and if it is damaged, replace it (trucks built from 12-15-03 to 4-1-04, P/N 4C3Z-6F081-AA; built after 4-1-04, P/N 1C3Z-6K786-BA). Seat the hose/pipe onto the intake manifold and torque the clamp (6 ft/lbs 12-15-03 to 4-1-04; 9 ft/lbs after 4-1-04). Broadcast Message 1329

 

Little slow tonight SB...

 

Vrrrrrrruuuuummmmmmmmmmmmmm......

 

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By the way welcome to the other club...the BIG BANG club....been a member for quiet some time.......6 times total, never took it in, fixed all of them beside the road..carry a extra blue tube with me at all times

 

Thanks to all for your help......I went to the dealer today and I have an apt. for Monday. I told them about the Ford Truck Enthusiasts Forum and I will take in a copy of all of your replys on Mon. Again thanks to all....Dick Hanford

 

Tim,

Did you get the new and improved "adhereable" intercooler tube? Mine hasn't blown off since..

Corey

 

They adhere about as well as sweaty butt cheeks on a hot day; thats a real joke from the mouth of Ford...

We have had two in in the past week that have the newer "better" tubes, blown off...as usual

Just some simple clasp, like the ones on the air filter, would be sufficient in preventing them from slipping off. The new ones are actually slipping out from between the clamp and flange underneath, leaving the clamp hanging where it was and the boot pops out from inside. Don't even bother to ask yourself how, it makes no sense...

Glad to hear yours hasn't come off yet though...mine hasn't either.

 

Not that I would know, but when those sweaty cheeks are on leather, you get some SERIOUS suction!

Corey

 

Bad analogy, from all sorts of directions

 

OK...wow made it past those posts...no I just clean very well with Brake Clean and tighten just a 'bit' more than called for...no problems since

 

I wish ford would not have given us PLASTIC tubing on the cold side.that severely limits what you can do to retain it... Mine they gave me a new cold side tube and put a HUGE stainless t-bolt clamp on it>>>which was what should have been there from the factory instead of the .99 chinese ring gear clamp.. Mine has not blown off yet>>>>But like anything else they did opnly the manifold fitting like this...So I fully expect the tubes to blow off further upstream at the worst possible time.... I hope it does not happen but it concerns me..