This happened to my intercooler somehow on my camping trip from cali to florida over the summer. Not sure if something hit it or a defect in the intercooler. Noticed it was damaged but no leak so i forgot about it till last night when i heard a hissing sound and found it had ruptured. Just seeing if anybody has ever seen this happen before.

 

Wow, never seen that! However, my opinion would be something hit it, based on the damaged fins below the leak and the side looks bowed out a little.

 

I remember reading a while back about a related issue with the '08-'10 trucks. When the front axle articulated, there wasn't any forgiveness with the radiator mount and the radiator would flex and bend.

 

Don't know if this affects the intercooler or not...