Intercooler problem

[crymepayz]

I have an 05 with juice/ ez stacked on it. I love the power but the other day I was getting on the freeway and was on it pretty hard I guess it was holding around 38 to 39 psi when the right side endcap blew off of the intercooler. Has anyone else had this problem and are there any fixes besides a banks unit? any help would be great. Thanks

 

[Tomeygun]

I have an 05 with juice/ ez stacked on it. I love the power but the other day I was getting on the freeway and was on it pretty hard I guess it was holding around 38 to 39 psi when the right side endcap blew off of the intercooler. Has anyone else had this problem and are there any fixes besides a banks unit? any help would be great. Thanks

Hmm. . looks like your plastic POS intercooler blew



Good thing is that dodge knows the problem and has replacement metal ones already at dealers



Dont worry be happy!



PS - Nice rig, get any pics with those big ol' tires?

 

[Snoxracer]

Boy am I glad I ordered my 05 late because it has the alumimum intercooler. I'm sure that I would of popped mine with the juice because I have see 40lbs of boost a few times! :--) But my question is has anyone had any problems with the intercooler on a stock truck!!!



Snoxracer

 

[lmills]

yes, some people have had stock trucks blow intercoolers. That's why dodge is going back to metal tanks

 

[DPKetchum]

For a while there the 6. 0 Ford sites there were lots of posts about them blowing out on stock motors. (As well as other things)Its been a while since a post on one of those.

 

[NLamke]

I blew mine at 34 psi. Took to dealer, the metal ones that they are replacing them with were on big time backorder. He overnighted me an 03 metal one, and put it in for me under warranty. Just had to move the A/C condenser brackets. Just don't let anyone put a plastic one back in!

 

[Truckie]

With all the problems that people are having with these plastic intercoolers is Dodge going to have a recall on them to replace them?

 

[nickleinonen]

With all the problems that people are having with these plastic intercoolers is Dodge going to have a recall on them to replace them?

recall... not likely



sure some burst stock, but most stock won't... with mods they can burst, then you either buy your own new 'updated aluminum version" or try and scam a warrenty claim and get DC to pay for a new one. .



if anything, they might put out a tsb on it, to be replaced with a new aluminum one if it does fail. .

 

[DPKetchum]

Not a safety item eaither. Just a failed part.

 

[NLamke]

I don't know about "scamming" the dealer out of an intercooler. I took mine in, told them about the chip, left it in the truck, and service manager told me the stock turbo should in no way be able to build enough pressure to blow the intercooler. Oh, and by the way, my chip was OFF when I popped my intercooler, so it does happen! Just wanted to clear a few things up before I get jumped on by someone (seems to happen pretty regularly around here)

 

[Kday]

Yeah they replaced mine with another plastic one! After a two week wait.

 

[nickleinonen]

I don't know about "scamming" the dealer out of an intercooler.

if you were upfront about the mods and they didn't care, that great... that isn't scaming in my opinion...



a while back there was a thread about something [i can't remember what broke?] and i suggested just going to the dealer and trying to get it warrentied without disclosing why it broke... oh, the poop hit the fan here with the moral police... i see both sides of the story... to me, it really doesn't matter which side you take on it [being honest and disclosing what happened, or being deceptive and getting warrenty for something that shouldn't be covered]...



hmm, i need to search and find what that thread was about now...

 

[hasselbach]

I don't know about "scamming" the dealer out of an intercooler. I took mine in, told them about the chip, left it in the truck, and service manager told me the stock turbo should in no way be able to build enough pressure to blow the intercooler. Oh, and by the way, my chip was OFF when I popped my intercooler, so it does happen! Just wanted to clear a few things up before I get jumped on by someone (seems to happen pretty regularly around here)

BULL you had the chip off! There is no way you were boosting 38 to 39 psi stock! My 05 goes no higher than 31 with the box off... (guess you got jumped on regardless of your efforts to come clean )

 

[lmills]

actually he said that it was with the box in the "off position", not off the truck. So yes it is possible. Most boxes still boost fool in the off position. So 37-38 is very posssible. Mine does it all the time

 

[hasselbach]

actually he said that it was with the box in the "off position", not off the truck. So yes it is possible. Most boxes still boost fool in the off position. So 37-38 is very posssible. Mine does it all the time

Off means off. . If yours is boosting in the off position, somethings wrong. Mine in off (3 trucks) doesn't add fuel or boost.

 

[lmills]

Most companies boost fool in the off position. TST, bully dog and pdq boost fool in the off position just to name a few. Boost fool does not mean it adds more fuel, it just won't defuel when it reaches the factory limit. Quadzilla doesn't but said they were able to if requested. That's just to name a few. And no, there is nothing wrong with my box, it's working just as it is designed to.

 

[NLamke]

BULL you had the chip off! There is no way you were boosting 38 to 39 psi stock! My 05 goes no higher than 31 with the box off... (guess you got jumped on regardless of your efforts to come clean )

Geeeeesh. Well, first of all I don't recall, nor can I find where I have EVER said anything about "38 to 39" psi. I've NEVER seen that high, even with the chip on. Second, the service manager where I took my truck, said that Cummins themselves are getting intercoolers to pop in stock form at high altitudes and max GVWR loads and have requested that Dodge not use plastic anymore. The way it was explained to me is that altitude plays a factor in boost as well, and where I live, 7 to 8,000 feet is a daily drive. I'm just telling what happened to me, so don't call me a liar. Two things I hate are a liar and a thief. If you're one, then chances are pretty good you are the other as well.

 

[DJennings]

Hasselbach,



Nlamke mentioned 34 psi boost when his intercooler failed.



crymepayz started this thread and is the one with 38-39psi boost at failure.