My cousin came by with his 03' 6.0 FX4, cc, sb. While pulling a gooseneck W/tractor his intercooler hose had blown off of the passenger side where it connects to the intercooler. I replaced it and started it up and as long as it was idling it was fine, when we brought the rpm's up to about 2500 it blew it off again. He's bringing it to the dealer this morning. Any ideas?

had that happen to me couple of months ago. took it to the dealer and they replaced the clamps on the short rubber hose on the turbo outlet. last weekend it blew off 3 times in 30 miles. called the dealer and now they say they had a bulletin to replace the pipe and hose. waiting on the parts. my buddy has a 6.0 and it has never happened to him, and his foot is a lot heavier than mine. go figure!

Ford has had that issue for years now even with the 7.3. Must me bean counters not allowing the engineers to spec a better clamp configuration.

Update - He brought it to the dealer and the mechanic told him that its a common problem and ford has no recall on it. All they did was flare the end of the tube where it goes into the hose and reinstall. The mechanic knew exactly how it happened, (pulling a load) he said the boost got to around 30PSI and it blew off.


Thanks for the input. As ya'll can see I hang out in the DURAMAX forum but just figured I'd give it a shot over here to try and help him out.


Charlie