I was at cruise control about 55 going up 6% grade with 9000 lb 5th wheel and hear a huge pop and then a tremendous rush of air .http://www.dieselplace.com/forum/images/smilies/help.gif On inspection of the engine, the intercooler line connection with blue hose has come apart. The side with the clamp is still in place, the side with the two rings is off the tube.

I could not get the hose to go over the pipe with the rings in place, so I took one ring off and used hose clamps to do a temp fix. It lasted for a while then came off again. I stopped at autozone and no codes???

Has anyone else heard or seen this? Truck has 5500 miles, fingerstick, egr block, no cat, no performance mods. ??????????

Clean the oil off the area, loosen the clamp and reassemble it, then tighten the clamp and then give it a bit more.

I cant, the side that came off is the side with the non adjustable rings (two of them) not clamps. Is there a trick to getting this back on?

Sounds like its gonna need a new tube then unless you can install a clamp on it. I would have the dealer address it if possible so you dont have a bunch of money tied up in it

Is this a common problem?? or am I just having a bad day. http://www.dieselplace.com/forum/images/smilies/frown.gif

Thanks for info.

bad day I'd say. Its not uncommon for the clamped end to come off becuase the clamp isnt tight enough.

Isn't their a tsb on this? I've read this happening before in this forum.. maybe do a search.. Their was something about oil from the crankcase pcv system getting into the hose and leaking from the clamp area. Is this what happened here?

I don't know how common this is, but the same thing happened to mine completly stock. The dealer said the clamps were loose, and there were no other problems that may have caused it.

we blow high pressure boots off all the time here at work. Sounds like a damn shot gun going off, kinda funny when the new guy gets it for the first time.

Happened to me while towing also. Truck ran very rough and spewed thick black smoke luckily i was near the house and dealer they fixed it withing 15 minutes. I'm sure the service was fast cuz i blew black smoke all across the dealer lot trying to get to the service area. They told me it was common issue.

woody, did you lose a clamp when it blew off?

no I did not lose the clamp. Mine has two different connections, one side has an adjustable clamp, the other (tube side) has two solid rings that sit in grooves of tube. The rings where still attached to hose.

The problem is you cant get rings back on, since they are not adjustable.

It is at the dealer right now, the guy I talked to said he has not had it come off the tube side before, usually off the adjustable clamp side.

I have an 04.5 also. Went out and looked, adjustable band clamp on all intercooler connections. ? Band clamp on each side and solid rings in the center?

I've had clamps go on me in a 'cab over' big truck. Talk about a wake up call. Sounds like the engine explodes, dust comes out the air vents, scares the buggers out your nose till you figure out what happened. :eek:
One thing not mentioned yet is you shouldn't drive very far under load with no boost on these engines. Much black smoke loss of power and extreme manifold temps. Disclaimer: my experience in this area is on a big truck but I think the same condition would exist in our p/u.

shortcut.

Yep, there are suppose to be clamps on both sides, so guess mine must have come off with the big boom, maybe was loose in the first place. Guess I will be carrying extra clamps from now on and making sure they are tight. Dealer has to order part, so truck is OOS for couple days. Thanks for everyones input.

I guess clamp tightness should be one of our preventative maitenance steps now also. :(