Well I am here in a hotel in Nampa ID with a blown inter cooler!! Just rolled over 38,000 miles towing 11,000 pounds. I was going no more than 70 down hill with mostly holding 65, big inclines were slowing me down to about 55-60. I was coming from Eugene, OR to Denver CO. I was losing boost max of 38 down to 22 to 12 to 6 and now 0 with EGT's going through the roof!! The inter cooler blew on the passenger side. Quad box on Level 2.

Now for the questions:
1. Where is the best dealerships around me that I can trust??
2. Inter cooler under warranty? Yes? No? I thinking no but have to ask
3. Is there anyone else (after market) that can install and have a inter cooler quickly?

Any help would be great....

 

that stinks. i believe the cooler should be under the 7/70 powertrain warranty.
call dave smith motors in kellogg id(milemarker 57? on I-90), that's where i bought my truck and trust them completely.

 

Very temping, but I kinda need one right away. Dave Smith is about 6 1/2 hours away for me.

Will I hurt the truck if I drive it with a blown inter cooler?? If I keep the EGT's down?? Or would it be best to stay where I am at and get a dealer to install one for me??

How hard is it to install one myself? How long would it take to do one by myself?? I have some tools but do not know if it is all I need. The intercooler would be like for like except for the plastic end caps..

 

Well, if you need to get back on the road, go get a two part epoxy and a ratchet tie strap. Pull the intercooler from the truck, ratchet the ends back together, fold the metal "fingers" back over and epoxy it where it seperated from the tank. Let that set-up "harden" and get on the road. Mine popped "seperated" and that was my quick fix. It got me to my destination which was about 750miles away, I ordered a new after market intercooler and had it at my destination ready to be installed when I got there.

Otherwise, see who can get you setup there in nampa. If you are headed through Idaho Falls or Pocatello, I can probably point you the right way to get a replacement.

 

that was one of the things I upgraded on my 05 when I started modding it was I bought an 03 intercooler and switched them out. the metal one handled over 50 psi. I dont know why there ever put plastic ones in there to start with. I will never understand that. I had a metal one on here for a while for sale before it sold

 

When a dealer installs one on warrenty it's aluminum. If you get an aftermarket it's still going to take overnight to get just like a dealer would that will be $0 instead of $1100+

Mark

 

Thanks CrashCade, I might try the epoxy if I can't get one until tomorrow and under warranty. Is it hard to pull?? How long should it take?? Is the cool twist and direct bolt on with no modifications?

 

So mostly likely the dealer will not have one on hand?

 

Called many different dealers from Nampa ID to Denver CO and all said no go for replacement in warranty. They also said it would be any from 2-4 days to 2 weeks. I was told by on dealer that the intercooler was on national backordered and could be up to 3 wks. So I will be making a quick fix here in the parking lot and ordering a new after market Cool Twist intercooler. Cool twist seems to be my best option to go for the price.

I will make sure I take looks of pictures for everyone to see.

 

Well I made to Denver, CO about 2:30 Wednesday morning. After CrashCade recommendation of using 2 part epoxy. It worked great, went from having 0 psi to 22 which was enough to get me to Denver. I also used a ratchet tie down inside to truck as added support. My epoxy job is not the prettiest but it sure work good. The pictures does not show it but I had to use epoxy almost all the way down the back side on the passenger side.

I did order the CoolTwist intercooler from City Diesel, it should be here by Monday.

 

I also pulled off the Quad chip, and with pulling up some big hills the truck slowed down to 45mph at the slowest with keeping the EGT's in check. I do not think that was not to bad considering pulling 11,000 pounds with a total GCVW to 20500 lbs and with a busted intercooler.

 

Cool patch job. Good to know it works "Just in case". Glade to hear you made it and the new one is on the way.

 

That is great, I am glad to hear that worked for you. I know it kind of saved me on one of my road trips...

 

Glad you got it patched enough to drive! I am glad I got a truck with an all-metal cooler. I too don't understand why they would put plastic tanks on them. Do they fail under stock loads? Maybe they engineered them just for stock boost levels? Either way, something under pressure like that should be made of materials that will hold it forever.

 

Wow, what a mess. Great job on getting that baby home. I too am glad they went back to all aluminum intercoolers for 07.