Blowing intercooler connectors
 

Noticed my truck was making a little extra noise lately.. Kinda dismissed it because I could not figure it out and did not have time....

Fast forward.....

Went to Rausch Creek this weekend and the truck towed fine... Trans got real hot going up the back road, but that was my fault and should have stayed on the highway....

Truck ran fine all weekend until the trip home....

Just getting onto the highway and putting the hammer to it....... BANG!!!!!!

Lots of smoke and no power....

Drove slowly to an underpass to pullover and take a look.. Found a loose intercooler connector from the turbo....Tightened it up.. Power braked the truck and it built boost.. .Great!!!!! Fixed, right???

NO!

Merging back into traffic, 40psi, and BANG!!!!! again......

Drove to the local truck stop and the same hose was blown loose again....

This time, I removed the air filter, loosened both connector clamps and the v-clamp off the turbo outlet. Realigned the turbo outlet with the intercooler pipe and tightened everything real good...

Kept the truck under 20psi and made it home fine....

Now I am kinda scared to push the pressure any higher.. Driving with the tuners off... Sucks!!!!!!!

What should I do? Buy new higher pressure rated connectors or clean, sand and rough up the current tube and connector and tighten back down..

Go to the store and buy some hair spray. Take off clamps and boots and clean ends of tubes. Spray hair spray on tube ends and reinstall boots. Tighten clamps. You should be fine, unless your clamps are weak, then get new clamps and use method above.

Thanks... I will steal some hairspray from the GF.. She will wonder why, but we wont tell....

Doesn't hair spray leave a flim? like carb cleaner does?

use cheap hairspray...not the good stuff.

aquanet from the CVS works great, it goes on wet, helps you slide the boot on, then dries and turns tacky and helps keep them sealed.

the best thing to do is get new constant tension clamp...the stock clamps wear out over time and then wont tighten up enough.

Make sure you use brake parts cleaner on the tube and boot before the hairspray. Mine kept blowing because there was a little oil residue on it.