I ve got a 2005 cc/dually with 5" exhaust,afe intake and quad chip. When towing on the first level of chip with about 7500 lbs I keep seperating the tank from the intercooler body on the hot side. Ford says nothing is wrong and it's the trailready bumper causing the truck to have not enough airflow. After the bumper was put on I didn't notice any coolant temp difference. Any ideas out there? Would a aftermarket cooler fix this issue?
intercooler blowing out
1 - 12 of 12 Posts
I'm not aware of a tank on the IC. I thought there was a pipe going from the turbo to the inlet of the IC, then a return line from the IC to the intake. Where exactly is it leaking?
I have not heard of a lot of stock IC's letting loose, so it is probably a poor connection somewhere. An aftermarket IC would eliminate the issue, but in any IC, there is always the chance of blowing a hose off, unless you take some serious measures (see my pics).
RL
I have not heard of a lot of stock IC's letting loose, so it is probably a poor connection somewhere. An aftermarket IC would eliminate the issue, but in any IC, there is always the chance of blowing a hose off, unless you take some serious measures (see my pics).
RL
Joined
·
366 Posts
Are you splitting the plastic end tanks on the ic, if so an aftermarket one would cure since they are all metal ends.
yeah its the plastic tank seperating from the aluminum ic body. This truck has blown five of them so far even in -30 celcius! I was just wondering if an aftermarket one would help although I'm concerned on the ramifications to the warranty on the motor as this truck has had about 40k in warranty repairs so far.
Joined
·
1,065 Posts
Wow... interesting. How much boost is the quad chip making your truck run? I've heard of 2 other trucks doing it only because the turbo's went haywire on the boost. That's the only thing I could imagine. My truck runs about 32-33lbs. and the stock I.C. is just fine. With 700 miles on it the boost pipe popped off that's it.
truck is putting out about 34-35 lbs of boost. Ford saysy it is due to the egt's being to high beacause of lack of airflow through the bumper. I find that hard to believe since it will still do it when very cold out and since the bumper install I've noticed no increase in coolant temps.
[ QUOTE ]
Ford saysy it is due to the egt's being to high beacause of lack of airflow through the bumper.
[/ QUOTE ]
Air flow has nothing to do with boost presure from inside the tank. the bumper will not have anythign to do with it. if the bumper is causing a blockage of the IC, it will just not alow it work at 100% meaning the incoming boost will be a little warmer. No real way to test this unless you tap the IC pice and put a temp gauge in it then take the bumper off and drive it. To much work for a test /ubbthreads/images/graemlins/wink.gif
You need to make your own IC or buy a banks or spacro unit. Lot of people make imtercoolers, Hate to say it but if there is a good local import shop that deal with turbo cars, they can point you in the right direction. Ford went cheap on the design to put plastic on it. Also with the banks kit you get 3" pipes and manderal bends for better flow. Also you might ask a radiator repair shop if they cant just weld metal end tanks on it instead of plastic.
You might check you local rig salvage yards. some time they have HUGE IC cheap. We cut up on and put it on a 84 GMC truck that has 427 with a 98mm turbo /ubbthreads/images/graemlins/wink.gif
The only way the bumper could cause a problem is if the ic is moving and hitting the bumper. I dont know how those bumpers mount so dont flame if that is impossiable.
Ford saysy it is due to the egt's being to high beacause of lack of airflow through the bumper.
[/ QUOTE ]
Air flow has nothing to do with boost presure from inside the tank. the bumper will not have anythign to do with it. if the bumper is causing a blockage of the IC, it will just not alow it work at 100% meaning the incoming boost will be a little warmer. No real way to test this unless you tap the IC pice and put a temp gauge in it then take the bumper off and drive it. To much work for a test /ubbthreads/images/graemlins/wink.gif
You need to make your own IC or buy a banks or spacro unit. Lot of people make imtercoolers, Hate to say it but if there is a good local import shop that deal with turbo cars, they can point you in the right direction. Ford went cheap on the design to put plastic on it. Also with the banks kit you get 3" pipes and manderal bends for better flow. Also you might ask a radiator repair shop if they cant just weld metal end tanks on it instead of plastic.
You might check you local rig salvage yards. some time they have HUGE IC cheap. We cut up on and put it on a 84 GMC truck that has 427 with a 98mm turbo /ubbthreads/images/graemlins/wink.gif
The only way the bumper could cause a problem is if the ic is moving and hitting the bumper. I dont know how those bumpers mount so dont flame if that is impossiable.
[ QUOTE ]
The only way the bumper could cause a problem is if the ic is moving and hitting the bumper.
[/ QUOTE ]
The only other angle I can conceive is that if the IC is somewhat blocked, and your heat transfer is really affected, the unit and the end caps will get a lot hotter when under load. Then, when you let off, the the air gets cold because when the turbo is not boosting, the intake air is ambient (cold). So maybe (and this is a stretch), the ends caps can't take the thermal stress back and forth?
I assume your IC was fine before the bumper upgrade?
Another issue could be a poor fit and that vibrations are cracking it. But that would have happened prior to the bumper install, unless the bumper install bent something in there.
RL
The only way the bumper could cause a problem is if the ic is moving and hitting the bumper.
[/ QUOTE ]
The only other angle I can conceive is that if the IC is somewhat blocked, and your heat transfer is really affected, the unit and the end caps will get a lot hotter when under load. Then, when you let off, the the air gets cold because when the turbo is not boosting, the intake air is ambient (cold). So maybe (and this is a stretch), the ends caps can't take the thermal stress back and forth?
I assume your IC was fine before the bumper upgrade?
Another issue could be a poor fit and that vibrations are cracking it. But that would have happened prior to the bumper install, unless the bumper install bent something in there.
RL
Joined
·
343 Posts
RL could be on to somehting. You said that the temps were as low as -30*C. Thats pretty dangum cold. The thermal stresses that the intercooler is seeing could be extreme if the bumper blocks that part from seeing much air. I mean what do charge temps get to mid 200's? I don't really know but thats a pretty good range in temps and the thermal stress could just be to great. And over time there's the tank busts... /ubbthreads/images/graemlins/shrug.gif
I have had an IC failure. What happens is the plastic end tank gets hot and warps, the gasket blows out and the tank comes uncrimped from the aluminum core. The tank pops off and no boost/power. I inquired about an all metal/aftermarket IC and was told they would consider that a "performance" upgrade.
Joined
·
583 Posts
Don't ya just love it when we IMPROVE on their design and they say it's a PERFORMANCE UPGRADE?
Well I guess their right, Cause their stocker doesn't PERFORM!!!! /ubbthreads/images/graemlins/rolleyes.gif
I just had a aftermarket C.A.C. installed and WOW does it help with the EGT's /ubbthreads/images/graemlins/biggrin.gif
Good Luck to you Candually. /ubbthreads/images/graemlins/smirk.gif
JR44
Well I guess their right, Cause their stocker doesn't PERFORM!!!! /ubbthreads/images/graemlins/rolleyes.gif
I just had a aftermarket C.A.C. installed and WOW does it help with the EGT's /ubbthreads/images/graemlins/biggrin.gif
Good Luck to you Candually. /ubbthreads/images/graemlins/smirk.gif
JR44
1 - 12 of 12 Posts
