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new 6.4 and New inter cooler, bloweing off upper boot

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Old May 26, 2026 | 07:35 AM
  #1  
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new 6.4 and New inter cooler, bloweing off upper boot

I have a 2008 Super duty 4x4 automatic with a new from the factory 6.4 motor that was installed less then 2 years ago. Aprox 14,000 miles.
It first blew out the stock intercooler and boot. So we replaced the intercooler with a AFE set up and replaced the air intake box and filter, and kept the stock down tube. Blew another boot and down tube and replaced it with a Afe 2 piece down tube and boot. On Friday I was heading over the pass from Seattle to Ellensburg and again, it blew a hole in the top of the intercooler turbo hot boot.
Again the motor and all of the components are new from the factory, The only thing I can think of is that the turbos are either stick or faulty. All of the work on my truck has been Done by Northwest Diesel In Marysville Washington and they are diesel specialist.
I am awaiting there return phone call as this happened over the Holiday week end. Does any one have any ideas for diagnoses?.
 
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Old May 26, 2026 | 11:24 AM
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I'm not as up on the 6.4, but I do know there is no such thing as 'new from the factory' as the 6.4 has been out of production for some time. Ford and International aren't building them anymore to my knowledge - I believe even the International version ended production in 2016.

I know of a place that REBUILDS them, US Engine Production, that does quality work. Then there's Jasper (Junkper) that I wouldn't use as a boat anchor. Jasper is far more common but I've had nothing but bad experiences with them, in respect to diesels.

As for your issue, I had a 6.0 that started doing that, and it was due to the variable-vane turbo's vanes getting stuck, creating too much boost that had to go somewhere. It's POSSIBLE you're experiencing something similar, but you've got a dual-turbo setup so I don't know where to tell you to go to diagnose that.

I would skip down to the 6.4 forum below, where you'll probably find a lot more, and more helpful, answers.
 
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Old May 26, 2026 | 01:26 PM
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See if there's any freeze frame data stored that shows manifold pressure when it happened. That would give you a direction to go in.
 
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