Intercooler hose comes off

[DavidGardner]

This happened twice now. The first time I was entering the freeway from the on ramp and got on it a little ( not WOT ) but accelerated briskly when I hear this loud whooshing sound and my egt starts to climb and my boost goes to nothing. Limped home watching the egt very close and soft pedaling it all the way (only 3 miles). When I looked the big hose from the turbo to the intercooler ( the one on the passenger side lower, going into the radiator) had come loose at the radiator conection. Put it back on and retightened the clamp end of problem. Recently while towing my 26 ft travel trailer up a long steep grade, just before the summit it does it again. Loud whoosh, loss of power, no boost and emediate and high temp rise on egt. Pulled over and dejavu all over again. this time the rear clamp had come lose and hose came off. Had tools with and reinstalled hose and tighten the cr#@%p out of it and everything is O. K. again.



I have the TST plate (230-605) and at WOT am running no more than 32 boost. What can I do to prevent this from happening again? See signature for other mods. Thanks in advance. Dave G.

 

[DarrellB]

Me too

I know you are valve challenged but you are running about the same boost presure as me, and the same thing happened to me last year. I went trough and tightend all the intercooler hoses and haven't had a problem since. Some of the clamps on mine weren't even fingure tight. I would just get them good and tight and you should be fine from here on out.



Good Luck

Big D

 

[illflem]

David, have you ever used a torque wrench to tighten the clamps to the recommended amount? The required torque is far greater than I ever would ever consider when tightening by feel, first time I used a torque wench I thought it was broken. In other words those buggers need to be really tight! Don't have my manual handy but seem to recall 20 ft/lbs, get a feel for how much it is at least once with a torque wrench. Mine have never popped off even with my 40 psi gauge pegged.

 

[DavidGardner]

Thanks guys. I have a friend (teacher) who has a shop manual. I will try to borrow it and get the torque values and retighten all of my hose clamps. I checked all of the clamps awhile back but only used a 10 mm socket and 1/4 inch drive ratchet. What feels realy tight may actualy not be.

 

[Joe G.]

The clamps have to be square with the hose too. If tipped or angled they will vibrate until they are square with the hose then they will be loose.

 

[Extreme1]

Check all of them. The hose must collapse or something as it ages because when I checked mine a couple years ago, several felt loose.

 

[Todd G]

There's no way to get enough torque with a 1/4" wrench. I too was surprised how much torque they call for.



Ain't it fun the first time you blow an intercooler hose? I thought a bomb went off under the hood. Then you see all the black smoke and think the worst.

 

[Garry Verheyden]

David,

Get rid of those crappy clamps you have on your truck and replace them with the spring loaded clamps. I had the same problem as you before, and would blow off the intercooler hose at over 38 psi. This happened a few times while towing on vacation. Then I'd have to listen to my wife ***** at me "Why do you have to wreck our truck by turning the power up so much?"

I replaced them with clamps that have a spring under the tightening nut and have never had a hose come loose in two years at up to 44psi of boost. I'm pretty sure Cummins sells them, if not call Piers 604-853-9396. They're cheap piece of mind.

Garry.

 

[Bob Wagner]

Napa carries SS Breeze clamps

just bought em today Stainless steel and heavy duty spring



3" clamp is Napa P/N 705-1525 4. 29 net each

 

[tschwab]

Originally posted by Garry Verheyden

Get rid of those crappy clamps you have on your truck and replace them with the spring loaded clamps.

DITTO!!!



My stock clamps came loose a few times... . then it finally happened, towing the 5vr down I-90 outside of Ellensburg, WA a hole blew through the hose.



Took it off, duct tapped it and crawled home. Part was replaced under warranty.

 

[C Schomer]

The spring clamps sound like an excellent idea, especially on the hot side with all the expansion and contraction! I wonder if you can get Bellville washers that small, for spring action? I made plugs and pressure tested the intercooler recently. Guess where I found three leaks - the hot side! They leak where the band lays over the saddle, under the bolt. I think the hose bunches up there and doesn't want to flatten out. Craig

 

[DavidGardner]

Thanks for the info Bob. I will go to napa tomorrow and get them. Probably pick up a set for TEACHER down in Toledo so we can do them on both our rigs . Thanks again guys.

 

[willyslover]

another source is a ferd dealer if ya don't have a Napa close by. . the clamps that ferd uses are spring and are a little wider clamp... [but you will be sporting a very small ferd oval logo on the clamp ]