I am having problems with my 2004 F-250 Super Duty 6.0L Turbo Diesel - late last year I was towing my travel trailer and the coupler (the blue tube that joins the turbo to the intercooler pipework) split open. That time I drove home slowly.

I replaced the coupler with a new one from Fords ($75). This weekend, out with the Trailer again and going up a steep hill. The turbo coupler sleeve blew off - we ground to a stop at the side of the road. Of course the clip holding it on had blown off and could not be found. I went to an Autozone and bought a jubilee clip which seems to be holding for now.

Questions: Is there any kind of glue/adhesive I can use to supplement the clips to make sure the coupler does not blow off again ?

Is there anything special about the Ford clamps that should work any better than my $2 jubilee clip -- any reason to change it ?

Thanks

PB

 

I would go to either NAPA truck parts, or a truck dealer and see what they are using. It seems like a clamp failure repeating itself.

When you put the blue coupler hose over the fitting make sure it is clean... Use something that disipates are evaporate real fast... Brake cleaner on a rag or something. Maybe there was oil on the fitting.

 

Get you some upgraded boots http://www.dieselsite.com/index.asp?...S&Category=571

You'll want a good clamp on it. Don't use a regular hose type clamp. Clean the pipe and boot up good for now. A shot of hairspray will help hold things together as long as you've got all the oil residue off.

The upgraded boots will hold better, but the tubes will need to be clean before the install.

 

Clean boot/pipe very well with brake clean or similar, and some hair spray will do wonders. Deff. make sure you have some good clamps on it, T bolt type.

 

Same thing happened to me today on a hilly switchback road (Rt 22 outside of Hollidaysburg Pa)
Just had the turbo housing replaced on Thursday at a dealer in Hollidaysburg and was returning to Jersey pulling a 4500 lb antique truck...sounded like the motor puked !!!
The spring clamp must have been over tightened because it snapped and that was all she wrote.

Broke down right in front of a little church on Rt 22 on the top of a hill and the Preacher came out to see what the problem was...I told him I needed a 2 and 1/2 or 3 inch hose clamp and maybe I could get it going again...he came back about 5 minutes later with a clamp that he got off of one of his congregates...I made him take 10 bucks for "the plate" and headed for home and it held !

The truck is a 2005 F-250 and has been a "barrel of headaches" since last May...NEVER AGAIN !!!

BT

 

Hello, I am new to the forum. Driving a 2005 f250 harley davidson 6 liter in the Netherlands. However, my stock valves from the intercooler need to be replaced. (the blue ones wich connect the intercooler pipe to the turbo and the other side to the intercooler on the passengers side) I am searching all over the internet, the forum and writing e-mails to several partdealers. All I am geting back is that they do not have the items. Can you please tell me were to buy the valves and how I must discribe them to get the proper ones? My alternative is to order the "Banks"intercooler set. I know, also very nice, but a lot more work and costs if you just want to replace the valves. I saw in this tread you call one side a coupler??

Hope you can help me out

 

Welcome to FTE. Are you referring to the rubber boots that connect the tubes to the intercooler? You can try this link http://www.dieselsite.com/index.asp?...S&Category=571

 

Thank you for your fast reaction Chris and the link. I allready found that site on the forum and wrote them an e-mail. But they told me they did not have the parts and didn't know were to get them from.

The valves I am alking about, when standing in front of the vehicle, the left side of the turbo (passenger side) there is a pipe who connects the turbo with the intercooler, that pipe has got 2 silicone valves, color blue, to connect the pipe on the upper side to the turbo (I think it is called the inlet) and the other side is connected the intercooler (/ radiator?).
They are still the original oem valves. The onley thing is that they have run out and I have to replace them.
I have found this article allready, this is the same problem I am having with my valves. But when doing a search on the internet I still haven't found a shop who can sell them for my F250.

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One problem that is not particularly frequent but worth mentioning is that some intercooler tubes near the turbo inlet are prone to cracking. The only thing is, they're prone to cracking on the side you can't see.
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This kind of a crack will cause a serious loss of power and will stump the average troubleshooter. The guys at Diesel Tech said the only way to find the crack is to slide a mirror underneath the tube.
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Already said before, but the boots on www.dieselsite.com are beefy! Mine weren't falling off but they were leaking from the CCV return (oil dusting from more than one joint). I bought the Diesel Site boots with the spring clamps. I cleaned the area (brake parts cleaner), sprayed on some hairspray, then used a lot of elbow grease to get those monsters on. Torqued down the spring clamps and have had no problems. After what it took to get them on, it will take A LOT for these babies to let go. If you are really concerned with them coming off (dieselsite claims to have tested them to 50+ psi), then you can order a second set of spring clamps for peace of mind. It's not cheap, but the setup is solid and I'd probably blow a hole in one of my CAC tubes before one of my boots let go !