Intercooler Cracked!

[JoshPeters]

The last few days I've been hearing a funny squeeking noise when I'm into the throttle a bit (over 20psi). Well last night on my way home from work it got really bad, and I was loosing power. I went straight to a friends shop and we ended up buying some pipe fittings to plug the intercooler piping, a regulator and tapped a quick-coupler on it to pressurize the system. Once we hit 10psi we found the intercooler cracked at the tank on the passenger side! We pulled the intercooler for a better look and found 5 or 6 of the passages at the tank cracked right where they meet the tank! Right now we are trying to get the truck back up and running, but obviously I need an intercooler! Anyone know where I can locate one for a decient price? I need the truck tomorrow to go to work!.



Thanx

Josh

 

[HoleshotHolset]

I got my 24-valve intercooler from PDR.



Try some bigger automotive radiator warehouses... they might be able to get you a replacement.



I believe the OEM is made by Valeo... .



Matt

 

[Duluth Diesel]

That sucks. Hey Josh, tell us about your fuel tank falling out from under the truck! I think someone pulls too many Dukes of Hazard stunts with their truck.



#ad

 

[JoshPeters]

It didn't actually fall out. I went out after work and noticed that something was hanging under my truck. So I inspected it and found the tank strap had seperated at the L shaped bracket to the actual strap. I removed it and welded it and got it fixed. Then this happens on the way home.



Josh

 

[DMC]

Go here--- glorad.com Fast service so far on two radiators. Very good prices and free shipping. You'll have to email them about the cahrge air cooler. Theres also one on ebay, $60. 00 do a search for dodge cummins.



Good Luck



Don

 

[JoshPeters]

Well, We Epoxy'ed the intercooler with a JB Weld like material, and it held 40PSI with our nifty home made testing tools. We reassembled it, but still have low boost and low power. We only gained 5psi from before. Any Ideas? We have checked the AFC, good, holds pressure and moves properly, Fuel pressure is at 28psi, and we switched my Air filter with Tims. We are leaning twords a fuel related problem, but the squeek really makes it a wierd problem. It may not be related, but it started just before all of this.



Josh

 

[SMorneau]

When your truck was on the dyno at Mikes in January Mike pointed out that you likely had a leaky head gasket as evidenced from the coolant blowing out the overflow at your radiator cap. As I recall the hose was disconnected and the coolant blew out onto the passenger fender well and battery area pretty well during the dyno run.



Hmmm... low power leaky head gasket :--)

 

[JoshPeters]

Good point. I don't remember seeing the overflow doing that, but I do remember him saying that due to the high boost pressure that I was running. The Coolant may have been cause I just topped it off on the way up there, cause I wasn't getting any heat. Once the engine warmed up in the shop (which it never did on the way up) the overflow started working. At this point I'm considering anything.



Josh

 

[JJW_ND]

Grab an oil Sample

Josh... . I would grab an oil sample it make sure internally everything is still sealed. A good sample will not guarentee no headgasket leak. Many leaks are external only (usually visable then). Mine was all external. Any bubbling in the overflow is a sure sign.



Any of the Zeigler Cat shops or Cummins North Central will have oil samples. Out Cat dealer here in Bismarck does 24 hr turn around.



If your EGTs are staying low when trying to make power, I think your right that fuel is being limited. Your AFC boost line is fine?



jjw

ND

 

[JohnE]

I picked up an oil sample kit at John Deere for $8. 94 including tax. They're on sale from $11. 19 plus tax.

Next over on the shelf was an anti-feeze/coolant test kit. I didn't get one so cannot quote pricing.

 

[JoshPeters]

We checked the AFC boost line, it's fine. Being an Auto it's just that short line, we also took the AFC off, and found that it's giving everything it's got at about 15psi, and does not leak. We are guessing it's fuel related. My EGT's stay low, I can't get them over 1200 no matter what I do. We are thinking it's related to my nose up hill hard starting issue. We are going to change the fuel lines and the filter, check and clean the strainer and see what happens.



Josh

 

[ChillyDog]

Sorry to hear about your problems Josh. I will give you a call Sunday. BTW, clean out your PM box, it's full!



Bill