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Could it be the fact that his truck might not have as hot of a tune as you do?
The tune is the exact same because I had my tuner on his truck for a while after I sold my 97 in 2004 and just picked up this 2000 a week ago and took the tuner back. We have the same intake, stock with a drop in K&N. On a side note, the dealership that I bought this from is a dodge dealer and they gave me a 30 day powertrain warranty with this truck and apparently it wont do me a bit of good as they have already told me that they don't know much about Ford PSD's and even simple things they don't have much of a handle on. I took the truck in yesterday for what they diagnosed as a bad carrier bearing when I told them I thougth that I had a bad U-joint. Picked the truck up today and still have the bad vibration and squaling U-joint. I would think that they would road test a vehicle after repairs. It vibrates so bad between 40mph and 55 mph everything in the door pockets rattles and the glove box door rattles.......they arent going to like me much when I go back there tomorrow to demand they fix the U-joint immediately cuz I'm not gonna be nice about it.
Are you referring to the clamps on the rubber boots that connect to the intercooler and air intake?
Yes, all the clamps for all the boots on the intake side.
There have been a few reports of torn boots, so it's best to take them all out, including the PITA orange ones underneath the Y-pipe. (Y-pipe must come out)
And examine them all for any pinholes or tears. Replace if necessary.
Cookie88 has a picture of a great boost leak finder that he built from plastic plumbing fittings available at your local hardware store. It requires compressed air to use.