Duct tape saves the day, whew!

[tschwab]

We were returning from a camping trip towing the 5vr, just got through Ellensburg, WA heading west on I-90 towards Seattle and I hear this very strange sound, kind of like a major sucking sound like there was a leak in one of the turbo lines, lost power and EGT's went way up.



I managed to get off to the side of the road as well as our friends who were also in-tow (thanks again TDR members Mark & Kim Sigafoos for all of your help) and started checking turbo hoses for loose clamps, couldn't find any loose clamps and I always make it a point to check them before each tow. Hmmmm.



One of the rubber pieces (as you face the front of the truck, it is on your right side - drivers side, down by the bumper) which connects the long tube which is connected to an air in-take which goes into the pump. Well, the small rubber piece (about 4"-5") connecting this tube to a cast iron piece down by the bumper, blew a hole right through the rubber! Sorry I don't know the names to all of these parts and pieces).



To make a long story short, we duct taped the hole by wrapping the rubber piece with many layers of duct tape, (a neccesity to carry in your truck along with a 7/16 wrench and deep socket to tighten those clamps), we had to remove it from the truck in order to do this, the worst part and the scariest was trying to repair your rig on the side of the freeway with cars and trucks whizzing by within 10' feet of you. Then I had to drive about another 120 miles home trying to keep my boost under 15 lbs, preferebly under 10, so I wouldn't blow the rubber piece we had duct taped.



Questions:

1. Has anyone had this happen or heard of it happening?

2. Will DC cover this part under my 5 year / 100K?

3. Does Cummins or DC make a stronger piece than what came stock?

4. What is everyone else doing to ensure your clamps stay tight with a pumped up motor?

5. I know Cummins uses a higher hp/torque version of this motor in other applications, what types of rubber connectors and or clamps do they use on those motors?



I figure I'm pumping out about 275 hp / 650 torque, I hit about 32 lbs of boost at WOT.



Any thoughts, comments, help or suggestions would be apprecited. Thanks-Terry

 

[HEMI®Dart]

tschwab,



This is the first time I've heard of a hose splitting. It looks like the OEM clamps are tough. I don't think they need upgrading.



I wouldn't think they would be covered under the 5/100 engine warranty. They're not really "on the engine".



I wonder how the Turbonectics Silicone intercooler conections are? They're probably stronger than the OEM ones.



http://www.turboneticsinc.com/catalog/silicone.html



We would need 2 SILICONE HUMP HOSES 3" I. D ? (Don't know exact I. D of the OEM hose's) for the turbocharger connector and air horn connector.



and two, 4" I. D ? SILICONE HOSE - HEAVY DUTY -BLUE - 1/4" WALL for the bottom intercooler inlet & outlet. I believe it's only in 3' lengths. The 2" piece would be too short I think. The OEM ones look like 1/8" wall.



It says on their web page:



SILICONE HOSE COUPLINGS:

"Top quality high-strength, high-temperature hose couplings. Multi layered fluro-silicone with fiberglass reinforcements. Additional sizes and lengths are available. "



Not sure on the cost. If its $$$ You could always "Go in" with someone on the 3' hose bulk piece, and cut it in half. 1 1/2 feet each guy should be plenty.

 

[Missouri Mule]

tschwab,

Don't quote me but dig out your warranty manual. Look up emission warrantied items. I believe the turbo is this catergory maybe the inter-cooler and some of it corresponding appendages are too.



While your at it check what is covered under the engine warranty



My warranty book is in the truck or I would look it up maybe tomorrow.

 

[Bob Wagner]

long time no see terry

On our return trip from SD 3 weeks ago.



I had low boost pressure prior to the vantage pull





I had the same boot let go at the turbo inlet as you described

except the clamp let go





where have you been?



PS Hemi&reg thanks for the addy

 

[HEMI®Dart]

I'll try tomorrow to get the I. D. 's of the OEM hoses. I will can Turbonectics Monday to get more info on Max temp & psi specs of the hose's. I very well may upgrade too.



Bob,



Lots of times the hoses will "Walk out" from under the clamps. I found the clamps weren't very tight from the factory. This really becomes more of a problem when you increase the boost over the stock rating. I re-posititioned the 4 hoses and tightened up the clamps. I think 3 had started to walk. No problems since then.

 

[Missouri Mule]

The federal emissions warranty covers almost everything that the Cummins engine warranty covers.



It is also 5 year or 100,000 mile. Covers exhaust/intake mainfold, fuel injection system, catalytic converter, injector, tubocharger.



This warranty is not the performance warranty, which states vehicle failed federal emission test, Maintained and operatede properly, big fine or loss of use of your truck.



But it doesn't look like hoses are covered( unless the some of the gas engine emission can be applied to the diesel engine, like vacuum hoses, clamps fittings and tubing used for these components unfortunatley turbo and intercooler), , but if you live in California their emmisions warranty elaborates a little more such as under intake mainfold charge air cooler is listed.

 

[Forrest]

Doesn't surprise me

Was on the creeper the other day & checked both of them, drivers & passengers side. They sure seemed too soft & thin. Any one else checked theirs? I would have thought this would be a thicker piece.

 

[KatDiesel]

Originally posted by HEMI®Dart

I'll try tomorrow to get the I. D. 's of the OEM hoses. I will can Turbonectics Monday to get more info on Max temp & psi specs of the hose's. I very well may upgrade too.

Let me know what you come up with, I'll get them jsut because they are blue. And if they are "better" then so be it.

 

[JohnE]

Hi Terry;



The only good part was being past the Vantage hill if you came from that way?



I carry a roll of mending rubber with me on any trips. This is stuff made for temp repairs of heaters hoses, etc. Not as wide as duct tape, but it is strong stuff.



Glad you made it home



Ever sorry about the DTT or TST , uh <em>preventative maintenance</em>?



John

 

[MikeR]

As you know there are a total of four rubber hoses in the intercooler system. The one off the turbo and the one off the intake horn are both 3" I. D,and it should be easy to find 3". The hard to find ones are going to be the two that come off the intercooler because they start as 4" and reduce to 3",and they make quite a bent to the black tubes.



-Mike

 

[HEMI®Dart]

Started out on the wrong foot w/ Turbonetics already

Thanks Mike,



I forgot that the 2 intercooler hose are a "transion type"

3" then taper to 4". Now I'm wondering if those hoses are "molded" to make the fairly sharp bend?



Kat,



I tried calling Turbonectics today. I wanted to see if the have the hoses listed (Kit) for the Dodge Ram CTD. I would think they would.



Not sure if the '94-98. 5 12 valve trucks use a different size then the ISB engines. I will get the p/n's for both if possible.



Called them. Got put on hold for 5 mins (they don't have a toll free number, thats BS too) . Ended up leaving a voice message to call me. Never called back. I'll give it one more try tommorrow. If I get jerked around again, I'll find another supplier. That left a "bad taste in my mouth" already.

 

[Elk]

Must be some monster on that vantage hill. My clamp slipped 3/4 of the way up 2 weeks ago, but always have the 7/16 deep well ready to pop in to action. The sad part is I check the clamps just before I left.

 

[HEMI®Dart]

Elk,



I'll check the on these clamps. They appear stronger than the OEM ones. They are specially made for Silicon hoses too.



#ad




I'm going to call these guys tommorow: http://www.mandiesel.com/0hoseandclamp.htm

 

[Bob Wagner]

same here Elk

I always check the hoses especially before long hauls and yes I have the deep sockets under the rear seat



Thanks for the input Hemi&regDart

 

[tschwab]

Thanks to all, you all have had some great replys that have been very helpful. I like the looks of those clamps and I will also try and get through to turbo techronics.



My truck goes into the dealer wednesday morning to get looked at by the tech, they couldn't answer me over the phone whether or not it will be covered under my 5yr/100k warranty. I told them that if it is not, that I want to be contacted before they preform any work, however, I got the general feeling that it would be covered.



I will let you all know what transpires. Thanks again.

 

[bbowe]

Heavy trucks have 'em

The constant torque clamps are standard parts on most heavy trucks. They are better for the silicone hose because as the silicone "flows" from the clamping force the constant torque ones will still apply pressure from the spring. You won't have to tighten them as often as a worm drive. Most truck parts counters should have them. If you are at a Kenworth dealer look for an F16-1006. The T300 uses the same size as ours, so they should have the one that is needed.



Mike R and I were looking at a T3 a couple of months ago and it also has the 4" to 3" adapter off the intercooler. That truck had a straight shot out to the charge air pipe, but maybe the adapter will make the upward bend the Dodge needs. So if the other suppliers don't work out maybe a truck place will.

 

[JohnE]

Vantage hill is only about 10 miles of pure hell. I cannot remember the elevation gain. I have always seen a vehicle pulled over to the side for either a tire or overheating.



We only suppply contant torque clamps on all water or engine air hoses. We generically call them <a href="http://www.breezeclamps.com/prodline.html" target=_blank>Breeze&reg; Clamps</a>. The smaller hoses get the true Contant-Torgue&reg; style. The larger hoses get a torque loaded t-bolt clamps. Cannot remember if they're Breeze brand or not.



John

 

[HEMI®Dart]

Talked to Turbonectics today. They don't have a listing for the Dodge CTD.



We need to take measurements.



This is what I got (94 12 Valve engine):



Need 2 hump hoses 3" I. D by 4. 150 long ( maybe its metric?)



Need 2 transition hoses, 3" to 4", 7. 5" long



Still not sure if the drivers side intercooler lower connection is molded at a 30º or 45º angle.



By looking at prices, it seems like this simple upgrade will be over 100 bananas w/ 8 clamps.

 

[tschwab]

Well here is the status so far: Truck is at the dealership, of course they dont have the part in-stock and need to order, should be in tomorrow.



So I ask the service advisor again, if this is going to be covered under my 5yr/100k warranty - Uh, I think so, she replys..... You think so? I say. I told her to call me if it was not. She said she thinks the part (a 3" to 4" rubber hose that is approx 5" long with the slight bend in it) will run about $80. 00 dealer cost. WOW - Can you say rip-off, DC.



Anyway, I will update when I get the truck back. Terry

 

[GOakes]

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