Hole in Intercooler tube - Diesel Truck Forum - TheDieselGarage.com
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post #1 of 9 (permalink) Old 01-22-2007, 12:28 AM Thread Starter
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Hole in Intercooler tube

Well, I finally got around to taking my truck apart to get my injectors sent in for a rebuild. I started with the driver side since it's much easier. When I took the driver side intercooler tube off I found a hole. Looks like it's been rubbing on the powersteering line. In the pic you'll notice a bunch of oil, which is powersteering fluid. I'll need to change this line since I can wiggle it and see fluid around the fitting. I'll take the tube to my aluminum welder guy to get it fixed. Any ideas on how to prevent this from happening again?

Tim




Early 99 Crew Cab Long Bed Lariat 4x4 7.3L PSD Primary Horse Hauling Rig
-Stage 1 160cc Single Shot Injectors - DP Tuner F5 - 60 Tow, 80 Econo, High Idle, Stock - NVK5 PCM thanks to DP Tuner
-Home Brew fuel system with Aeroquip socketless fittings, socketless hose, and Aeromotive Regulated Return
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post #2 of 9 (permalink) Old 01-22-2007, 12:40 AM
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The tube is aluminized steel, so any old welder will work just fine!

01 F-250 SC PSD,210k,16 Isspro Gauges, AFE-2,CCV Mod,IAH delete,map reg,Modded H2e, 6.0 IC, GTS Hybrid injectors, Studs, 910 Valve springs, Forged rods Water injection,Swamps tuned, MBRP 4" dual's, Aero, 6" tip's, 100 axl tank, 4" Revtek lift, 37-14.50-17 TOYO MT's 469hp and 1068tq...

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post #3 of 9 (permalink) Old 01-22-2007, 12:51 AM
 
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As to preventing any further carnage, try slitting a piece of vacuum hose and slipping it over the PS line, it will act as a buffer between the two
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post #4 of 9 (permalink) Old 01-22-2007, 03:57 AM
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Quote:
Originally Posted by powrstrkn'
As to preventing any further carnage, try slitting a piece of vacuum hose and slipping it over the PS line, it will act as a buffer between the two
Yep...thats what I did. Found some old rubber fuel line, cut it lengthwise, placed it around the offending portion of powersteering line, and zip-tied it in place.
post #5 of 9 (permalink) Old 01-22-2007, 04:30 AM
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I just beat mine over with a 15# sledge hammer? Was that wrong?

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post #6 of 9 (permalink) Old 01-22-2007, 07:23 PM
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The pipes on the early '99s are aluminum not aluminized steel. I don't think they started the aluminized still until like '01. Any little thing that rubs on the aluminum pipes will rub a hole in it. The best way to fix it is to keep it from rubbing. Sounds like something got a little out of place because those two parts shouldn't contact in the first place. Did your power steering line get a little tweaked?

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post #7 of 9 (permalink) Old 01-22-2007, 07:28 PM
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Quote:
Originally Posted by gtspowerstroke
The pipes on the early '99s are aluminum not aluminized steel. I don't think they started the aluminized still until like '01. Any little thing that rubs on the aluminum pipes will rub a hole in it. The best way to fix it is to keep it from rubbing. Sounds like something got a little out of place because those two parts shouldn't contact in the first place. Did your power steering line get a little tweaked?
Sweet! Thanks, now I know how to weld aluminum with my mig welder!!!:shrug:

01 F-250 SC PSD,210k,16 Isspro Gauges, AFE-2,CCV Mod,IAH delete,map reg,Modded H2e, 6.0 IC, GTS Hybrid injectors, Studs, 910 Valve springs, Forged rods Water injection,Swamps tuned, MBRP 4" dual's, Aero, 6" tip's, 100 axl tank, 4" Revtek lift, 37-14.50-17 TOYO MT's 469hp and 1068tq...

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post #8 of 9 (permalink) Old 01-22-2007, 09:01 PM
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Well you CAN weld aluminum with a MIG welder if you have the right wire. Reguardless from what I'm told the later pipes are aluminized steel but the earlier ones ARE aluminum.

'96 F-250 Extended Cab, GT'S injectors, GT'S intercooler install kit, custom turbo kit with a little HX40, Swamp's BIGEST oil.
466 on #2 only
739 with NČO

13.544 in 1/4 mi!

"If you think you can do a thing or think you can't do a thing, you're right." Henry Ford

Yeah I can keep up!:Thumbup:
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post #9 of 9 (permalink) Old 01-22-2007, 10:17 PM Thread Starter
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A quick magnet check confirms they are aluminum.

Early 99 Crew Cab Long Bed Lariat 4x4 7.3L PSD Primary Horse Hauling Rig
-Stage 1 160cc Single Shot Injectors - DP Tuner F5 - 60 Tow, 80 Econo, High Idle, Stock - NVK5 PCM thanks to DP Tuner
-Home Brew fuel system with Aeroquip socketless fittings, socketless hose, and Aeromotive Regulated Return
-4" Lift 285/75R16 E Nitto Dura Grapplers - 5" MKO Aluminized Exhaust w/6" Stainless Tip - Pair of Optima Red Tops - Napa 6637 Air Intake filter - Triple Gauge A-pillar Pod w/Autometer UltraLite:Trans, EGT, Boost - CCV Mod
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