Blown intercooler

[DLRutherford]

At 54,000 miles the gasket between the plastic end pieces and metal center section of the intercooler on my '05 3500 blew out. I was pulling an 11,800#

5th wheel up a slight grade. Luckily I had guages and spotted the drop in boost pressure (4#) and high EGTs (1300+ degrees) so avoided engine damage. $1,300 for the new intercooler (all welded metal) which Dodge refuses to cover on my warantee since it is not a lubed part. Dodge changed to welded all metal intercoolers in '06 when, I believe, they realized that the plastic/metal design was faulty. I have heard that the plastic/metal intercoolers routinely fail at aroun 75,000 miles. I need to hear from others with same problem to help support my argument with Dodge.



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'05 3500 Crewcab, Airaid filter; Banks High-Ram intake; 5" turbo back exhaust(no cat); turbo fooler, guages; air-lifts; basicly stock with some dress-up body mods: fender flares etc.

 

[rscurtis]

Don't run to the bank with this, but that should be part of the emissions system warranty.

 

[rashwor]

I can't help...

as I have almost 200k on my original plastic tank intercooler.

 

[NavyDood]

as I have almost 200k on my original plastic tank intercooler.

Prolly built mid week.

 

[Bob4x4]

At 54,000 miles the gasket between the plastic end pieces and metal center section of the intercooler on my '05 3500 blew out. I was pulling an 11,800#

5th wheel up a slight grade. Luckily I had guages and spotted the drop in boost pressure (4#) and high EGTs (1300+ degrees) so avoided engine damage. $1,300 for the new intercooler (all welded metal) which Dodge refuses to cover on my warantee since it is not a lubed part. Dodge changed to welded all metal intercoolers in '06 when, I believe, they realized that the plastic/metal design was faulty. I have heard that the plastic/metal intercoolers routinely fail at aroun 75,000 miles. I need to hear from others with same problem to help support my argument with Dodge.



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'05 3500 Crewcab, Airaid filter; Banks High-Ram intake; 5" turbo back exhaust(no cat); turbo fooler, guages; air-lifts; basicly stock with some dress-up body mods: fender flares etc.

Since your truck is modded you are out of luck if they were to send out a corporate rep. Why sweat the small stuff.

Buy an upgrade and move on

 

[Joseph Donnelly]

For a while Dodge was replacing the plastic tank intercoolers under warranty. If you have to buy a new one, the kind of money you cite will get you close to the much better BD intercooler, or another aftermarket unit. See my discussion on intercooler design in TDR Issue 68, p. 90.

 

[MAshley]

I can't help you other than to say I have heard it a bunch of times before. but mostly back in 05 06 time frame when people were passing 54K miles. . Really that is low millage. Anyways I think $$ wise you would be better off finding an aftermarket intercooler and or finding one in a junk yard. There should be plenty of rolled or water damaged trucks that would be perfect donor for a new intercooler

 

[Bob4x4]

if you were local I have a good 06 take out available

 

[AHolt]

I would buy a after market intercooler, before I paid that
for a stock one. After market intercoolers are larger.

 

[rashwor]

if you were local I have a good 06 take out available

Bob, do you still have the '06 take out?

 

[Bob4x4]

Yes I do... .....

 

[rashwor]

PM'd you Bob.

 

[seafish]

I am SO glad my truck, build date April 2005, has the all metal intercooler !!

 

[rashwor]

Yep. That is what I am hunting for mine. Got a crack in the top driver side mount where it joins the tank.

 

[AH64ID]

I got mine covered under warranty at 48K miles, well outside of the normal 3/36.

But if you have to pay for it yourself DO NOT get OEM. There are much better for the same or less money.

Dodge only offered the plastic end tanked coolers for the first part of 2005.

 

[JMarketos]

I got mine covered under warranty at 48K miles, well outside of the normal 3/36.

Not sure if the I/C is considered part of the powertrain ? The 05's came with 7/70 powertrain warranty. But I guess that's beside the point. Mine came with the plastic intercooler With an auto trans, I heard (read... ) one mode of failure was such as going up a hill with the cruise control on and if the trans happened to downshift under load, the boost would spike and pop one of the tanks. I encountered this a few times (before I installed the GV). I have a boost gauge and can say first hand the boost can spike well above 30PSI on a downshift like that. I never did have an IC failure- I installed a Banks IC before that happened. Bigger IC made a noticeable drop in EGTs, also. Best cure for that would be to have a 6-spd, but wife (at the time) wanted the auto. Not sure what I'll do with the original IC- maybe hang it on the wall or make a coffee table out of it.

 

[rashwor]

Ain't no warranty here as the truck has 203k+ on it. Plus, it is a surface crack that is not affecting boost and I am wanting to do this as pm rather than be broke down waiting on parts.