6.4L Dieselsite Engine & Intercooler Boot Set

[mick1955]

Well after installing a Dieselsite boot set I took my truck for a ride tonight. When I got to the highway and took off, maybe 1/3 throttle, I heard a loud whooshing sound, truck lost most of its power. Pulled over and opened the hood, and found that the intercooler tube came loose from the turbo. Tightened the damn thing again, took off at full throttle and it blew off again. Limped the truck back home cleaned the damn oil off of everything, tightened it again and it blew loose before I made it to the highway. These boots have no flex in them and the intercooler pipe does not properly align with the turbo and the lower connection on the intercooler. Guess I’ll be reinstalling the old boots again, unless anyone has any suggestions.

[Pahrump]

I have never seen or used the boots for the new engine, but I have had the dieselsite bboots on a couple 7.3's never had an issue with them, they actually solved my issue of blowing boots off at 25psi of boost on those trucks.

[OOWeaver68]

Well after installing a Dieselsite boot set I took my truck for a ride tonight. When I got to the highway and took off, maybe 1/3 throttle, I heard a loud whooshing sound, truck lost most of its power. Pulled over and opened the hood, and found that the intercooler tube came loose from the turbo. Tightened the damn thing again, took off at full throttle and it blew off again. Limped the truck back home cleaned the damn oil off of everything, tightened it again and it blew loose before I made it to the highway. These boots have no flex in them and the intercooler pipe does not properly align with the turbo and the lower connection on the intercooler. Guess I’ll be reinstalling the old boots again, unless anyone has any suggestions.

did you try to get them tighter...lol:D

[mick1955]

I tightened the crap out of the. It's just the one that keeps blowing off. I ended up putting the original on the bottom of the intercooler tube, it's flexible. Then I tightened the one that comes off the turbo till I thought it would break. Better not come off in the morning. Have to take the wife to the Woodlands for surgery. Leaving around 5:30, way too early for me!!!

[OOWeaver68]

I tightened the crap out of the. It's just the one that keeps blowing off. I ended up putting the original on the bottom of the intercooler tube, it's flexible. Then I tightened the one that comes off the turbo till I thought it would break. Better not come off in the morning. Have to take the wife to the Woodlands for surgery. Leaving around 5:30, way too early for me!!!

i think you have to use some elbow grease... you come on, give it your all...lol

[mick1955]

OOWeaver68 - I'm not that old yet. Better watch it you young kid!

[JoshDavis]

Well after installing a Dieselsite boot set I took my truck for a ride tonight. When I got to the highway and took off, maybe 1/3 throttle, I heard a loud whooshing sound, truck lost most of its power. Pulled over and opened the hood, and found that the intercooler tube came loose from the turbo. Tightened the damn thing again, took off at full throttle and it blew off again. Limped the truck back home cleaned the damn oil off of everything, tightened it again and it blew loose before I made it to the highway. These boots have no flex in them and the intercooler pipe does not properly align with the turbo and the lower connection on the intercooler. Guess I’ll be reinstalling the old boots again, unless anyone has any suggestions.

Remove the boots spray them down with brake cleaner, along with the intercooler tubes and turbo outlet. Let this dry, no oil residue whatsoever. Or it will defeat the purpose. Go steal your wifes can of hairspray (aquanet=glue) ha! spray the mating surfaces one at a time and assemble while still wet. Let it dry for 10 or 15 min and give it a spin.

[mick1955]

JoshDavis - Thanks Josh, I will definitely give it a try.

[Gerry]

OOWeaver68 - I'm not that old yet. Better watch it you young kid!

Yes you are :D.......


PS. I hope every things ok with your wife Paul.

[mick1955]

Gerry - How about flat tires on the Ranger, or maybe the tow vehicle on the way home from the races, all 6!

[Goolsbymd]

I got the same boots, and have zero problem and actually fit better than the stock ones, make sure you have the correct one on the correct pieces, also CCV mod and call it a day.

[mick1955]

Goolsbymd - Due to the hurricane I still haven't had time to get the lower one back on, but hopefully will soon!

[Gerry]

Gerry - How about flat tires on the Ranger, or maybe the tow vehicle on the way home from the races, all 6!

Now that's just mean....... :p.

[nczn]

So much to learn....

[mick1955]

Yes there is so much to learn. The best part is the people here that will help you along the way. And, there are a lot of them. I know the one that I have learned the most from on this site, and some others is Pahrump.

[Triggertx]

If I remember right the clamps call for a 60lbs per in. torque. I went with the boots because I was blowing the upper right stock boot. So bad that the fan shroud is busted pretty good from tube "launching".

Like said above, brake cleaner to clean surfaces. You could also use a few of the original clamps to double up.

[mxracer732]

mick1955- have you had any more problems w\boot blow off?
I may be installing my boot set this week.

[mick1955]

mick1955- have you had any more problems w\boot blow off?
I may be installing my boot set this week.

No sir, not at all! They are much nicer than the stock boots. I did do as JoshDavis recommended and have not had another problem. Think part of the problem was that I didn't clean everything as I should have. I getting ready to order another set for the wife's truck...

[Kimminau2]

No sir, not at all! They are much nicer than the stock boots. I did do as JoshDavis recommended and have not had another problem. Think part of the problem was that I didn't clean everything as I should have. I getting ready to order another set for the wife's truck...

That is good to hear. I will be doing that as well. Mine blow off every 5-600 miles. I have tightened the #$%# out them and it does not matter. I spoke to diesel site about them and they had said just tighten them up as much as you can. I did not try the hairspray/glue trick though.

[mick1955]

Kimminau2 - Just make sure you clean them real good, and like you already said tighten the crap out of them. After that, I don't think you will have any problems!!!!!!!

[jeepman]

I've been running these boots since last summer. When I first installed I had the same problem except I was blowing the lower intercooler boot off. I cleaned them up real good with brake cleaner and double clamped the boot to pipe connection and it fixed the problem.

[Kimminau2]

As I stated previously I have the dieselsite boots. They keep blowing off. I have done the clean and aquanet trick but it did not do any good. I have since blown holes in 3 boots. 2 times on the upper boot and once on the lower boot.
I have talked with Bob at dieselsite several times and he is also at a loss as to why this is happening.
I had a brain fart earlier and thought I would check with you guys to see if there is any merit to my thought. It seems as if the pressure is much higher than it should be since it keeps blowing the hoses off and blowing holes in them. I don't know what you guys see, but when I am just cruising on the highway at about 65 (towing a load) on pretty flat ground my gauge is reading 35-40 psi.
I don't know where that reading is taken, before or after the intercooler. But is it possible that there is a restriction in the intercooler? If the intercooler is restricted I would think the pressure would build up much higher on the inlet side than it should.
Another thought I had was that the aluminum intercooler tube gets scorching hot really quickly. After only short distances it will burn my hand through a pair of thick gloves. If there is (or can be) a restriction the temps would also be higher on that side wouldn't they?
Most of you know alot more about these than I do, what do you guys think?

[mick1955]

Someone also suggested usig the new clamps and the old. May want to give that a try...

[underpressure]

Def. something going on. My boost while cruising does not come close to this, not even towing my 32' center console. (11,000 lbs) Also, the alum. does not get hot at all on mine. Hope someone with some knowledge will chime in here.

[underpressure]

Someone also suggested usig the new clamps and the old. May want to give that a try...

Paul, you tow alot of heavy shit often, right? You seeing this kind of boost and hot intercooler tubes? Wonder what tune he's towing with? Hell, I tow the boat with the 275. Dunno....

[Kimminau2]

I am towing with the 210. I tow about 20k most of the time. I know that is a lot with this tune, but from what I understand this should not be causing the problem.

BTW, the alum tube gets hot like that towing or not.

I think I can get them to stay on now, by using the stock clamps, but now it is blowing the boots.

[DriveOne]

I tow a 40ft gooseneck that weighs 10,000 and throw another 6-12000 of surface pipe on. The 210 tune keeps the boost up around 30-35 on flats but will jump to 40-42 on some inclines. However, the old 210 had the tendancy to reach up to 56 psi. I tried the 275 on an empty load and it seem to boost alot like the new 210. the only thing was during shifts the trailer buck was ungodly. This has all been with stock boots so I don't know if it helps.

[Kimminau2]

What is the "new" 210? I am using my original 210 tune.

It helps in so far as I should not be blowing boots just because of the tune.

The original question does anyone know if the intercooler can become restricted and if it can is there a way to test it?

[JUnk14]

heres an idea, stitch weld a bead around the ends of the tubes. it creates a stopper for your clamp to hit. as far as the oil in them, take the breather off and run hose underneath truck. then plug the air intake hole that was for the breather. two simple fixes no more slid off boots and no more black oiles tubes or boots!

[DriveOne]

What is the "new" 210? I am using my original 210 tune.

It helps in so far as I should not be blowing boots just because of the tune.

The original question does anyone know if the intercooler can become restricted and if it can is there a way to test it?

The revised 210 was released 2-9-09. It was mainly created for those with surging issues but seems refined overall. You should definitely try it. See Nutties notes on how to get it.

I hardly see any way the intercooler could be restricted but i'm no mechanic. I forgot to mention I had the same problems but with an early 6.0, blowing boots and even blew the side off the intercooler. The dealer tried blaming aftermarket exhaust and tuners on it but I hadn't made those upgrades. The only other explanation they had was the veins were sticking on the turbo creating massive overboost at certain rpm, however they never followed up on the turbo nor did i have any more problems. I traded the truck shortly after.

[Kimminau2]

Sweet, I missed that. Thanks.

[Gerry]

Something does seem right.... I tow 12,500 lbs at least once a month and with the 210 tune cruising at 75 mph on flat ground I see less then 20 psi on the DD. Now if I get to a slight incline it will hit 30-35 in a hurry but comes down as soon as I'm at the top.