I've got a '99, 145k, stock Turbo, Superchips D-Box, K&N FIPK, 4" Exhaust, and full gauge setup.

I had this issue before, and never thought too much about it, but while towing a relatively light (5k) trailer from Moab to Denver i blew the intercooler line off the turbo 4 times. Always on the turbo side, and always with the pressure clamp at full tightness. I'd be crusing up a pass, turning ~2000rpms, ~1100 egt (bit hotter then normal) at almost full boost, and then "Poooooof" i'd have massive boost loss, instant skyrocketing EGT's and a huge air leak, and 0 power whatsoever. Pull over, same issue. Reattach it, keep going, and it would happen again on the next pass.

Couple of people i've talked to say "this is normal", but it doesn't sound that way to me, it's annoying not being able to haul up the passes without worrying about blowing a line off!!!

Anyone have any thoughts as to why this is happeneing, and how to cure it? There's no oil on the turbo side where the hose attach, so it's not "lubricated" and sliding back off easy.

 

It is not normal for it to blow a boot off. You can get some hairspray and then clean things up and spray the hairspray around the tube and boot. Re-assemble things with the hairspray wet and by time it dries you will have a difficult time trying to take it apart.
Tom

 

I agree. Take the boot off and clean everything around it real well and then soak everything in hairspray and put the sucker on. I'll bet it doesn't come off again.

 

I had that happen to me also twice on the same trip late last summer, towing in the mountains. Pulled over immmediately and retightened but not as tight as I could get them, and blew off again(same inlet at intercooler) about 2 hours later and about 30psi boost. Again retightened as much as they would go, and all has been fine since(tough to do when engine that hot). When we got to campsite and it had cooled down I rechecked and noticed boots are getting soft from heat. I'm trying to match up some from hiway tractors, as they are much thicker and will last many more times over stock. I did come across somewhere on the board that a company was selling upgraded intercooler hoses for our trucks, but didn't save it. Maybe somebody can chime in with info.

 

I was told that it's a symptom of my turbo going out- can anyone confirm/deny this?

 

I would DENY it...

It not a sign of the turbo failing its a sign of overboost (stock setup) or failing clamp / hoses.

If a turbo was t ostart failing the compressor blade would start touching the housing and there would be in / out movement of the shaft. Possibly even oil burning or oil loss.

I heard of many people doing the hairspray trick now... It seems to work well...

 

I believe Piers has better boots for olur trucks.

 

Save yourself the headace and just get some high pressure boots from Piers, others sell them too, they are thicker and alot tougher too. No comparisson to the old ones.

Cheers, Kevin