How many miles before yours bit the dust?

I am trying to decide what mods I am going to do and an intercooler just isn't in my budget, so how much abuse can the plastic one take?

 

I would'nt touch it till it goes out of warranty. That way if it does go the dealer will put in the better one for free

 

So DC has good intercoolers for these trucks, but they choose to just drop in a crappy one instead and wait for a fault in it before they give their customer what they initially deserve for dropping 40+ thousand dollars on their trucks...I'm sorry, but I would like to think that this isn't true...

Derek

 

If the stock intercooler (plastic) goes south, you may just get another plastic replacement. The real problem is where and when the stock unit will fail. (there is no warning) It will never be near a dealer, or when you have the time to wait for the replacement you can count on that. The other problem is when they go south, you lose almost all the power. You run very very high EGTs! If you are towing, out in the back country, in the mountains, you are in a big problem! So upgrade with an aftermarket unit, better performance and piece of mind!

 

Mine hasn't yet. Yet!!!
The replacement is not a plastic one. It just happened to be an early '05 cost cutting mess that the likes of you, I and others got saddled with.
There's no rhyme or reason to when they blow either from the reading I've done. A few have blown just idleing in the driveway, others during a sled pull and anywhere in between. Chances are slim that you can get the dealer to replace it now, but hey ya never know, might be worth asking. Can't hurt.

 

OK, is this puppy going to blow on a stock truck or more likely a problem on the bombed ones?

 

does the 07 5.9 come equipped with the plastic version?

 

I doubt you have one since you have the G56. Seemed to be only the '05's with the nv5600.
But to answer the question, sure, bombs that will boost more will be more likely to cause the failure.

 

Anything built after Jan 1 2005 SHOULD have the metal IC. Might be a couple weeks differential there but no more.

 

Nope their is a TSB out about them. You blow a plastic one you get a metal one. They put them in for a few months and then figured out the mistake they made. They only came in the 05. My thought is they designed the new intercooler with out telling the people at Cummins what they were doing. Then in 04.5 the bigger turbo went in and Dodge was stuck with some plastic intercoolers. Well let me rephrase that. The people that bought early 05's were stuck with plastic intercoolers.

 

You hit the nail on the head!! That is what happened to me, I was about 50mi from my house with my 35ft flatbed with 2 jeeps on it, passing a 45mph car and it blew. That thing sounded like a gun shot from the fromt of the truck , not a good thing at 1am on the wat home from Canada with 4 friends, boy did I ever get some poop from my friends for that! You will get very high egt's, no power (35mph max) and a loud air leak the rest of the way, btw only tow with the Edge on lev 1. Took it to my mod friendly dealer (sold me the edge) and they put a new metal one on. My truck is an early 2005, build date 8-12-04

 

I've hit 40+ psi numerous times and my plastic one is still alive. I'm sure I'll replace it someday, though. Preferably at my choosing and not because of the loud pop .

 

Yeah, looks like the bean-counters struck again! My '05 was built in September of '04 and it's plastic. Guess I'll be waiting for the meltdown, too!

 

My 05 was built in March 2005 in Mexico and I have the plastic intercooler. Sucks!

Sid

 

One reason I am happy with my non-intercooled Cummins.