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anybody heard of a intercooler blowing up?my buddys 2003 psd 7.3 had this happen and I was curios if anyone knew why or what would do this. The only mod was a 4inch exaust he was pulling a 36ft fifth wheel
Yes, I have heard of this happening. But only on the intercoolers with the plastic end tanks, so mostly I've heard of 6.0's blowing them. However, Ford did put some plastic end tanks on the 7.3 near the latter part of it's life span. When they blow, it's typically one of the side tanks that becomes seperated from the core. The plastic end tanks are just crimped to the core with some tabs that are attached to the core.
The fear of blowing an end tank was one of the reasons I switched my intercooler from the stock 6.0 I had to the Spearco one. I can take some pretty long trips away from home and can't afford to have an IC end tank blow off on me when I'm several hundred miles from home and on a schedule.
That is the reason I change mine. I have a Banks intercooler installed. It is a monster. I did not think that I was going to get it into that little area without taking the front end off.