Modified Intercooler

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Nov 25, 2009 | 06:02 PM

Hardrock_F250

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Joined: Sep 2005

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From: Denmark, SC

Modified Intercooler

I went to Charleston SC this morning and while trying to accelerate on the on ramp to I26 the motor sputtered and blew white smoke again. This also happened a month ago and I pulled the intercooler off and drained about a cup of water out of it. After it did it again today I said that when I get back home I was going to fix this problem or at least make it easier to drain the water. I took the intercooler off and there was more than a cup of water in it. I drained it out and proceeded to install a drain ****. The bottom would be the best place but I would have to weld an aluminum piece to it to add depth for the threads. On the side of the intercooler there is a spot that is thick and low enough for the water to drain out. I drilled out a 7/16 hole, tapped it with a 1/4" pipe tap, placed some thread tape, and tighten the drain **** into the intercooler. So far it works great, just start the engine, open the drain **** 1/2 to 1 turn, and the water pours out as if it was on an air compressor tank.
I can't post the pics but here is a link to my albums.

Ford Truck Enthusiasts Forums - Hardrock_F250's Album: Intercooler Mod 2008 F350 6.4

Nov 25, 2009 | 06:50 PM

senix

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From: Frederick, MD

That is great, maybe the mods can add it and the pics to the tech folder as "Intercooler Fix"

Nov 26, 2009 | 12:30 AM

mick1955

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Joined: Dec 2007

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From: Hendersonville, N.C.

There is a tsb out for the problem you are describing. If your truck is under warranty I would contact Ford. 08-25-1 12/22/2008 Diesel Engine - White Smoke In Cool Humid Conditions

Here's a link to the actual tsb:

Tsb 08-25-1 - TheDieselGarage.com

Nov 26, 2009 | 06:20 AM

senix

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From: Frederick, MD

Quote:

Originally Posted by mick1955

Those that are having problems are not always successful in the new intercooler either. Some still have the issue. It is a design flaw. I am not an engineer but that is my belief.

Nov 26, 2009 | 07:41 AM

Maxium4x4

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From: Ohio

Quote:

Originally Posted by senix

That is great, maybe the mods can add it and the pics to the tech folder as "Intercooler Fix"

Done and done...

Great information for everyone

Nov 26, 2009 | 09:18 AM

ssharber

Tuned

Joined: Jul 2007

Posts: 413

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From: Tennessee

HardRock has had the new intercooler fix, but is still getting condensation. This is an excellent fix. Glad to see you got it taken care of.

Nov 26, 2009 | 09:22 AM

Hardrock_F250

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Joined: Sep 2005

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From: Denmark, SC

Quote:

Originally Posted by mick1955

I had that done the first of this year but when the humidity is high the moisture still collects/condenses in the CAC/intercooler. Now I can drain it out without having to take the unit off. I live in SC and the humidity has been high here for about two months straight.