05 intercooler hoses blowing off??

[Hooper]

I'm sure one of you wise gentlemen have seen this. What could be causing it? The dealer couldn't help, nor could a local so called "PSD specialist". The first couple times the lower passenger side blew off and this morning it was the upper hose at the front of the engine. Always happens when going up a small to moderate grade, both unloaded and with my horse trailer in tow.

 

[keanoknick]

Is everything stock? fill in your signature and tell us about your truck so we can better help you.

Make sure that when you put it back together, that you thuroughly degrease
all contact points, both inside the boots, and on the outside of the pipe, intercooler,
and intake elbow. As they will get an oily biuldup due to the CCV system.

I was still blowing them off, after cleaning them, so on recomendation from Banks Engineers,
I used a coat of permatex brand, High Tack, on all mating surfaces after cleaning,
and prior to assembly, to sort of glue them on, I haven't had any problems since then, even when drag racing last weekend, and I regularly hit 34-35 psi of boost.

 

[Hooper]

It's a bone stock 05 F250 crewcab 4X4 SB, nothing special. But thanks, I'll try a good cleaning and the high tack idea. Its been months since this has happened, and never with this particular hose. Heck the truck has less than 20k on it.

 

[bigbrother44]

A contractor I had do some work for me has an F450 that was doing the same thing. Apparently, once the hoses blow off, you have to replace the clamps too. He said the dealer said...that the whole assembly expands and contracts so the clamps have to be flexible...apparently they get too flexible?

 

[NASCAR Mike]

If you overtighten the clamps it will blow off also. There should be a torque rating to tighten the clamps up to. Could your clamps be damaged?

I would think that proper torque, clean surfaces and high tack glue will solve your problem.

 

[spindrift]

Take a look at this TSB:

 

[cgrayson9]

I had my hose blow off pulling a 12,000 boat in the middle of the desert. It was a 115 degrees. We tried everything to reconnec the hose, but nothing held. After dropping the boat and driving 150 miles with no boost to the dealer, he said you must replace the intercooler hoses at about 30,000 miles...they just fail. He did, but the next time towing, I blew the intercooler!!!!

I replaced the stock intercooler with the Banks unit. Wow... more power and no breakdowns!!!! I really like it.

 

[F350DRW1]

You can also lightly sand the inner surface of the hoses and outer surface of the tubes to rough it up [gotta be clean of course] before you apply the High-tack. This was what I did the last time the top tube blew off. At one point it was coming apart about every week.