Engine/Transmission (1998.5 - 2002) Intercooler hoses blowing off?

[STPdieselhp]

This is not my truck, its a friends truck. The only mods that he has is a superchips and a k&n filter. He keeps blowing the intercooler boot off on the pass side closest to the turbo. There is no oil in the hoses and he has bought a new boot and new clamps and it will still blow off under a pull. Doese anyone have any ideas or has anyone experienced this before? Thanks alot.

 

[KcoleKennyc]

This happened on mine and I had to tighten them really tight. been about 3 years and they have not moved since.

 

[Cummins724]

I learned a trick... . spray the surface where the boot slides onto with hairspray... . then just tighten the clamp down till it is ready to strip... . then double nut it. Worked for me with 55psi.

 

[MrBee]

One thing I have found is that in most cases the surface of either the boot or the intercooler pipe has a residule (however small amount) of oil. I have cured the issue with a light sanding and wiping the intercooler pipe and the boot/hose with MEK. Then I coat with Hairspray both hose and intercooler pipe, assemble and let it sit until dry. Problem cured. I have also used motorcyle handlebar grip cement. Either way, make sure the surfaces are super super clean.

 

[GCULP]

also make sure the elbow from the bottom of the turbo is perfectly aligned with the intercooler tube, mine came back from service work at the dealer and kept blowing the hose, rotated the elbow about 5 degrees and BAM, all good for over a year.

 

[NoSeeUm]

What is his maximum boost pressure?



Jim

 

[ACoyle]

I tried all of the suggestions above and they all worked to varying degrees. Finally, I replaced the clamps on the boots, cleaned the metal surfaces with alcohol, and used high tack. Upon comparison of the clamp to the new one, I believe it wa the clamp all along.



This was on my '99. My mods are in the sig, I had about 35# boost.



AC

 

[mmkummerfeldt]

Had same problem & replaced with BD Intercooler Hose Kit (BD-1045210) $199. 00 from Geno's Garage. They come with better clamps. No problems since. Mel

 

[oldiron]

Any idea what to tighten the clamps that come with the Genos kit to?