Engine/Transmission (1998.5 - 2002) cleaning the intercooler

[Wyomingcowboy]

I am in the process of rebuilding my turbo and cleaning all the hoses I can that have oil in them and am thinking about the intercooler. How would I go about that? I can take it out easy enough (except for having to dismantle the whole front end to get the dumb thing out) but what would I use to clean the inside of it? That orange cleaner stuff? Simple Green? Solvent?

 

[Joe Mc]

I'm pretty sure the shop manual calls for a solvent base cleaner. You probably need to use one that will evaporate, as if there's some left in the inter-cooler it could be curtains upon start-up. I'm wondering if a rad shop could do a cleaning without ruining it ? ? ?

 

[SRath]

I wonder how well an aerosol can of transmission cooler flush would work? When I get an auto transmission rebuilt, the shop sells me a can of that stuff which dissolves all oils, blasts the cooler and lines clean and clear, and evaporates out cleanly with some compressed air.

 

[Wyomingcowboy]

i'll look into that.

 

[Joseph Donnelly]

I use non-chlorinated brake cleaner if I can find some without toluene or xylene. Or, gasoline would work. Be sure to blow dry it to prevent an engine runaway on startup. To remove the intercooler on a Second Generation turbo Diesel, you will have to remove the radiator and front bumper. These two items do not need to be removed on a third Generation truck. you will need to remove the intercooler to clean it thoroughly. Don't leave any residual oil in it or it will carbon up and lessen heat transfer. Also be sure to get any aluminum bits from a blown turbocharger compressor wheel out of the pipes, intercooler, and intake area of the engine.

 

[Wyomingcowboy]

Thanks Joseph

I don't have any metal bits as the turbo didn't blow up. But I did manage to blow up myself because of the turbo! I had a brain fart and didn't pay attention to the reverse threads and twisted the shft off at the nut. I called HTTTurbo and they explained a new shaft runs about $650. Is there any use for a shell of a turbo??

 

[Joseph Donnelly]

The wheels and shaft are probably the biggest cost, along with labor to precision balance the unit after rebuilding. This is probably a good time to explore options in the aftermarket turbo world. Companies like BD Power and High Tech Turbo have a variety of options from rebuilt stock to slightly modified stock to completely aftermarket turbos.