Engine/Transmission (1994 - 1998) Loses power under heavy load

[Diesel Dually]

I was pulling a heavy trailer up a steep hill yesterday when the truck suddenly lost power and started to make a loud noise, almost like boost air or exhaust leak. My RPM's were at about 2200 when this occured. I pulled over and let off the throttle and noticed a puff of brown smoke from the exhaust. I don't know what my EGT was at the time... but I have towed heavier up worse hills with no problems and I don't just hold it to the floor, I am willing to get the transmission in a gear that will not work it any harder than needed, even if it means crawling up the hill. After that the truck will run fine as long as I don't go more that about 1/2 throttle. When I give it any more go pedal the noise returns, power drops and it starts rolling out the black smoke. I had to park the trailer and go get my '05 which towed the trailer with no problem. Any ideas!!? Thanks in advance...

 

[hsmith]

Probably blew the inlet innercooler boot. Time to upgrade to silicone boots.

 

[Diesel Dually]

hsmith,



You were right. I got a chance to look at it today and the only one that popped off was the inlet boot to the intercooler. Thanks for making my search easy!

 

[bmoeller]

I used to blow my stock boots off. Used hairspray on them, and haven't blown one off since. I've also had to tighten up the bolts on the intake manifold (the flat plate that the air horn and grid heaters are attached to).