intercooler history

[CJBaldwin]

Intercooler problem

I'm sure the answer is here somewhere, but my DH doesn't do computers, so guys, "don't shoot the typist"... ..... I have an 05, 3500 with automatic transmisstion at about 20,000 miles, the intercooler leaked and caused a dramatic loss of boost while towing a heavy 5th wheel. The metal prongs that hold the plastic end tanks to the core bent under high boost and caused the leak. A dealer in Montana replaced the intercooler under warranty. The next day, after towing only 40 miles the new intercooler started leaking. This time from a crack on the back side of the nipple that receives air from the turbo. The same dealer, again replaced the intercooler. Now,two years later at 52,000 miles, I can hear a boost leak at very high boost. 25 PSI and above. I can't find it because it's a small leak at very high boost. Any idea how to diagnose this? My truck has never had any engine modifications, it is stock. Thanks for you input. CJBaldwin

 

[MStrain]

If you haven't already purchased a intercooler, I saw this one on ebay, good deal, the guy wants $500 for a Banks, it says it is new but was damaged in shipping and has been repaired. May be perfect, but I would ask the guy some specifics about what happened to it before you buy. The seller seems a little clueless, the item title is "Banks Turbo air cooling radiator" , I guess thats close enough.





eBay Motors: Gale Banks Turbo Air Cooling Radiator For Dodge Truck (item 200124798077 end time Jul-07-07 19:14:03 PDT)

 

[231jasonS]

I can't find it because it's a small leak at very high boost. Any idea how to diagnose this? My truck has never had any engine modifications, it is stock. Thanks for you input. CJBaldwin

You can put the whole system under pressure by caping the front of the turbo and pumping air in the system through a schrader valve. You can by this tool or just make one.



I used a piece of 4" sewer pipe and cap with a schrader valve screwed in one end, then a rubber connecter and some clamps. with the system under pressure and the motor off you can hear the air escaping and find your leak/s. A little spray bottle of soapy water may help find any leaks also.

 

[CodySanders]

all i can tell ya is never ever buy a bd intercooler. the first one i had ballooned out on me and the fittment is so poor the bumper brakets rub the intercooler. the second one the welded in some support rods and it only took two days to blow out the welds and have a hole the size of your pinky in two spots. the third one was sent back to me and looked just as bad so i gave up and got another brand. by the way after 3 transmissions, 2 intercoolers, 2 boost foolers one bad hose clamp and a bad set of twins i will never use bd again, not even if they paid me. what a worthless bunch of junk. and there support and warrenty is the worst. will not pay what they say they will and lie lie lie to the end that they didn't say they would pay for it. out of all the companies out there i feel that bd has to be the worst even over chrysler and all their crap they have done.

 

[CJBaldwin]

Jason- Thanks for the quick response. One question, Does the output side near the intake manifold need to be plugged off also?

 

[231jasonS]

Jason- Thanks for the quick response. One question, Does the output side near the intake manifold need to be plugged off also?

No just the input, the engine will have a litle pressure lost but we've been able to pump them up to 40 PSI for testing purposes.



Good way to see if any of your boots are leaking. I did this test to my 04 and found 2 leaking boots and a bad weld on the corner off my stock metal intercooler.

 

[CJBaldwin]

Jason - thanks for the great tip on the intercooler, tried it exactly as you said and it worked perfectly and I was able to repair them both. The first was a loose hose clamp on the intercooler and the second was the small hose going to the boost guage. It was passing air at high boost but wouldn't blow off - secured it with a wire tie. Thanks again for your help. Chris



P. S. - Now we need to teach Chris how to use the computer! hehe! Leslie

 

[231jasonS]

chris/leslie... your welcome im glad it worked for you. Now you have a "custom tool". Thats what TDR is for.