1950 miles on a new 04 EC LB 4x4 2500 D/A, towing open car trailer with 2000 lb off road car (about 3500lbs max) travelling up about a 5% grade on a very narrow two lane road, approx 55 mph. Tranny drops down to 4th (i think I remember this), all of a sudden "BOOM" heard and felt from the engine compartment. Instant dark cloud appears from exhaust, and severe power loss. Road has less than 12" on the right, so no where to pull off, about 1/4 mile from top of grade. Motor is running, but slowed to about 15 mph to get to a point where we could safely pull off the road.


Open hood, coolant starts to boil out, smell "burnt" something, and see the blue rubber hose connecting the turbo, and I think is the intercooler pipe is blown off. I called GM roadside and told them of the situation, and that I could put the pipe back in the hose and try to drive it home. They told me it might void my warranty, so I called for a flatbed. Truck is now at a dealer 80 miles from home, their service department doesn't open til monday. My truck is 100% stock.


Any idea what might have happened here? Anything I should specifically ask this dealer to check in addition to the obvious? My brother who was with me, also has an 04, and he said that his is a lot quieter than mine, especially at part throttle, dealer I bought it from said this was normal. I poked around here and see I might need a new flash to stop this. So I'll ask them to try that.


Thanks in advance...Edited by: 4-by-4

I'd put the hose back on and run it. When the hose popped off you lost all boost, thus the black smoke. Noisy when they pop off too. Just put it back on and make sure its good and tight.

Put it back on and drive it......Heard that many times on the pulling track....You should here one bust loose at 80 psi!!!!

Sounds like like the charge air cooler hose. You will not have power without it.

Put it back and tightent he clamp.

Go on your way!

Maybe not a bad idea for all LLY owners to check those clamps and tighten them up to avoid having this happening at the wrong time like 4-by-4! Mama JJ tows our 5ver by herself for long distances and wouldn't have a clue what to do if this happened! JJ http://www.dieselplace.com/forum/smileys/smiley4.gif

The exact same thing happened to mine on 9/18/04. It's still at the dealer over 75 miles away. I was just told they probably won't have parts until Oct the 8th. They (CHEVY) also said there are four others waiting for the same parts (the charge air cooler tube).

Just wanted to thank you for the responses....Yes, it was just the charge hose. There is apparently a TSB for this, according to the dealer that is fixing it. I could have slid the hose on myself, but wasn't about to do anything that would allow GM to weasel out of the warranty...especially with less than 2,000 miles on the truck..;) Hopefully this will be the only time it leaves me stranded and that nothing else was weakened by the failure.

What does the TSB say.... "Make sure clamp is tight"?

Got to smile at this one LOL


Just got back from Vegas and on the way over from San Diego running along at 75 loud pop and lots of smoke and no power. I was thinking that now GM will be able to find the problem with the motor thinking it must of broken in half. Called for a tow but I could still get 15mph out of her and the next place to pull over was 1/2 mile away. The truck was turned into a rolling billboard along the 15 freeway smoking like no tomorrow!! Got to the ramp and looked under the hood to find the turbo pipe disconnected and way to hot to touch. Called GM back and told them to put a hold on the tow truck and I would try to reconnect the pipe. Nice guy comes by with tools and it is back on in a flash. CHP stops by to make sure we were ok and back on the road. Might of got the turbo dirty inside cause it smokes now when you have your foot in it. Ran fine the rest of the trip.


Dealer just called to say my new 05 is in so I will let GM have their truck back with one more thing to fix!! Maybe it is wishfull thinking but I hope I don't have to come here much more to cry on your shoulders after I pick up my replacement truck.


DennisEdited by: ALUMINATOR

What does the TSB say.... "Make sure clamp is tight"?


I believe it reads: Tow vehicle to nearest Dodge dealer for clamp tightening.

I was looking on the "ask the techs" and I think there is a TSB on this item. if iI remeber right it said tighten clamps to 53 inch lbs. I'll try to find it again and try to post a link.


edit: DMAXALLITECH could you help? I think this is the right topic?


(It was your post so thought I'd ask you)


Oil in Intercooler (http://dieselplace.com/forum/forum_posts.asp?TID=15942&PN=2), I'm not certain this is the same issue and i'm not good enough with the features to make the link.


Thanks in advance if I'm right, if not I guess i have some more learnin to do.


Tom C.Edited by: OmyLLwhy