Has anyone else had problems w/ there intercooler? started w/ a loud jet like sound, smoking more and more, till the noise went away and boost droped, then MORE and MORE smoke less and less power exhaust temps higher and higher then check engine light code p0299 turbo or intercooler fault. Had a friend hold the brake and put a load on the engine and could see the tank pushing away from the cooler. Why would anyone build an intercooler half plastic and half aluminium? It's under warrenty, but is it just going to happen again? should I upgrade to aftermarket?

 

Go with a Hellmann intercooler. You won't be disappointed.

 

They learned there lesson.....the new one will be all aluminum. That was a short build run they used the plastic ones.

 

it's likely they'll replace it with a all metal cooler since that's what they're making now. If not, I'd try and request one.

 

I think I'll push for that! When (what year)did they start using the all aluminium ones?

 

from what I understand... the plastic cooler was only on the 05's. All the rest are metal.

 

Let warranty fix it. The new one will be metal.

 

I also have not heard of any problems after the intercooler is changed. Many are running greater than stock boost with the stock metal cooler. Only part of 05 trucks used the plastic intercooler and many have broken. The replacements are the metal ones again and like above let warranty fix it.

 

they switched to plastic on 05 and back to aluminum on 05 according to the diesel mech at the dealer I go to.... he said not IF but when it pops we'll replace it with a good one.... hope that means warrenty

 

Not sure what my original was built of, but after I hit a cow at 70 mph on October 30, 2005 with only a little over 4k or so on odometer, the newly installed intercooler was all metal. No problems since repair.

 

On the 2005 if you have a NV5600 you had the plastic intercooler. When the G56 came out they went back to the all metal intercooler.

 

It's at the dealer now so we'll see tomorrow!

 

I've heard the hellmann intercooler will lower egt's substantially..like 200+ degrees. Far more effecient then the stockers.

 

Anyone know about the average mileage these things go at when the truck sees an easy life of no towing or mods? Would like to have a spare for piece of mind but would really rather have the dealer replace it, either way its going to be inconvenient when it does go.

 

Same here. Mine has seen 40psi many times, and I know it is a matter of time. I spoke with the dealer and they won't replace until it goes.