i finally got wild and crazy and built something to pressurize my intake. i found a couple of leaks! first one was on the boot the goes from turbo to intercooler had a nice slice. the second one was the actual intercooler itself
down at the bottom. so i grabbed my fancy pressure tester thingy and thru it on my parts truck.... that intercooler is even worse

replacing the boot did help a little. any suggestions on the intercooler problem? radiator shop? maybe a powerstroke ic? how about 2nd gen. ic?

oh well can't be too bummed i like old trucks and this is what you get. i can only imagine how good it will go when fixed

 

WOW!

I was right along.. woop woop. Good you found that leak, it should have some more power/boost now

Well anyway, that just stinks that both intercoolers leak, Can you hear the leak or see it or what?

Nows a good oppurtunitry to upgrade,,, 2nd gen cummins or a 99-03 7.3 P/S intercooler, whichever one you find first and cheapest. I think a P/S intercooler is easier but I'm not sure... 2nd gen i/c's are tall.

I would just upgrade it, rather then getting a stocker fixed.

 

its amazing what you find when you pressurize the system. My intercooler leaks also.

 

How'd you pressureize it?

 

x2???????i just go with a PS IC

 

http://dens-site.net/Dodge_CTD/Intercooler/

Doug

 

How bad is it leaking? As long as it's not more than 5 psi in 30 seconds it will be fine.

If you know somebody who is handy with a tig welder it can be patched.

 

Bradshaw,
I had one fixed in my Ford 9000 at a shop in Belfast.
Its Doaks machine shop.
I had them take out the whole bottom row and weld it back together. I don't remember how much but it sure was cheaper then a replacement. If you want to go the powerstroke route check Green Point in Brewer. I got my 7.3 cooler from there for 150 bucks.

 

here is my tester .

Hook it up to the turbo and regulate it to about 30 psi. You will loose pressure though an open valve but spray soapy water on the boots and lines and you will find the leaks real easy.

 

it leaks pretty bad, along the bottom row. i will probably upgrade just won't be for a little while. got a getrag swap that needs to get done.
on a different note getting almost 20mpg out of my truck not bad for a brick with wheels!