24v charge air system

[me4osu]

This is my first post, so be gentle. I recently purchased my '98 3500 CTD used with 60k mi. on it.



A couple of days ago, I noticed a hissing noise near the radiator. Upon further investigation I found that the previous owner had placed a piece of plain old hose on the outlet of the intercooler to the charge air tube. Not only is the hose inferior to the stock item and not made for this application, it is leaking.



I asked my friendly Dodge dealer for a replacement hose, AND THEY WANTED $136. 00 FOR IT!! Needless to say, I asked them to keep it.



Does anyone know of a cheaper, yet good quality replacement?

 

[Bob Wagner]

you need to purchase silicone heater hose

Check out and call www.thepowershop.com



They stock the hose should be less than $30. 00

 

[me4osu]

Bob,

Thanks for the tip. I called the powershop, and they said that one of their suppliers is doing development work on an aftermarket 3" X 3. 5" 45 deg. ell. However, it will be some time before they release it.

I am working, with one of our vendors, on my own replacement using an even size ell with the reduction formed on a new stainless steel charge air tube. I will be taking all of the measurements this weekend when I remove the square 180 return to install my boost pressure tap.

When I have installed the new pieces (and logged a couple hundred miles on them), I'll post my results (if anyone is interested). Initially, the total looks to be half the price of the DC hose.

 

[Bob Wagner]

Sorry

I was thinking of the hose not the formed piece sorry.



Keep us posted and Welcome aboard!

 

[Turboclamp]

I should be able to get you one of these hoses if you still need it.

I do research and development on charge air systems and therefore have access to some O. E. M. suppliers. The price is probably in the $40. 00 range. If you still want one, I will get the actual cost for you. Let me know. I can also get a good deal on the spring loaded T-Bolt clamps that should be used on these connections. The factory ones are just a garden variety t-bolt

clamp with no constant tension features.

 

[me4osu]

OEM hose & spring clamps

Turboclamp,

That sounds like the price I was expecting to pay. If you could send pricing and availability of the hose and spring clamps, I would greatly appreciate it. Another thing would be how I would pursue ordering and payment. Thanks!!!!

 

[work2muchplay2little]

Here's another source http://shop.airflowonline.com/Merchant2/merchant.mv?Screen=CTGY&Store_Code=AFSI&Category_Code=IHC I've had good service from them.

 

[Bob Wagner]

Hey Kurt

Thank you for the addy

 

[tgbol]

I usually go to one of the big truck dealers around here to get parts like turbo hoses and clamps. International and smaller CAT engines use hoses the same size as ours.

 

[Turboclamp]

The big truck dealerships are a good source for heavy duty charge-air supplies. I have purchased heavy duty spring loaded t-bolt clamps from them. They are expensive through the dealers. A 4. 25 inch clamp cost me $16. 00. I needed it and my distributor didn't have it. (I would have paid about $8. 00. ) These ARE the fix for intercooler hose blow-off. The spring compensates for changes in the connection due to heat, pressure, hose relaxation etc. . There is a standard duty spring t-bolt clamp avaliable, but it dosen't perform as well as the heavy duty version. I'll attach a picture to show the difference.

 

[me4osu]

Progress report

Well, I have installed all of the pieces and logged around 1000 mi on them. I have not pulled anything so the highest boost I have seen is around 27 psig. Everything is right where I put it, no slippage.



The 3. 5” 45 deg. hose ell and the 3. 5” X 3” hump reducer are stock Donaldson Air Products hose fittings used on tractors and construction equipment. The tube is 3. 5” X 18” X 0. 065”wt 304L stainless steel tubing with 1/8” tall TIG beads stitched ¼” back from the ends. The clamps are constant torque type worm drive that use bellville washers instead of springs. The clamps aren’t as good as the ones that Turboclamp has, but my rig is not heavily bombed, and these are a little cheaper.



Prior to install, I deburred the crap out of the tube to make sure nothing is going to come loose. I cleaned the ID of the tube with some Berryman’s B-12 and cleaned the OD of the tube and IDs of the hoses with some evaporative electronics cleaner. The only hard part was installing the 45 on the outlet of the aftercooler; after I bent the inside of the wheelwell out of the way, I had to stretch the hose a little to get it on the fitting. I tightened the clamps to where I thought they were about to strip, and they visibly compressed the rubber.



Because I am not an expert poster yet, please see all of the pictures of the pieces and the invoice in my gallery. The total cost is almost $90. 00 dollars, but if I ever need to replace a hose piece, I’m looking at $10. 00 buck max.