Intercooler Leak Test

[Gasuout]

Trucks been down boost . At first it was 2 psi and noticed it is down about 7 psi now full throttle . Figured I better check it out . I borrowed the kent moore tool for intercooler testing from a buddy at dealer . Been putting it off for a while now checking it . Tool comes with 1 plug and a second plug with regulator and gauge . I disconnected both intercooler tubes and installed plugs . Didnt even have to add much air to find the problem . Air was pushing out right away bad . Cracked intercooler again . Second time now . Driverside between radiator and intercooler . 8-9 " crack about 1/8" off tank seam .

Im not really suprised . This has happend before in the same place ,exactly the same crack . The front end of the kodiak is on rubber mounts . The driverside intercooler tube is pulling on the intercooler obviously . Probably from Glamis Dunes or some of the nasty offroading I give the truck .

This tool comes in real handy for chasing down leaky intercooler .

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I was pretty sure it was this again . Took some hard hits this season in the dunes .

Johnny

 

[bullfrogjohnson]

That sucks Johnny. I believe you win the award for being that hardest on hard parts.

Are you gonna try to redesign the way the intercooler mounts to prevent it from happening again?

 

[LB7Diesel]

Did the plastic crack? I alway's thought that was a very poor decision to put plastic sides on the intercoolers due to the heat cycles. Seems to make them brittle and crack from vibration.

 

[Gasuout]

That sucks Johnny. I believe you win the award for being that hardest on hard parts.

Are you gonna try to redesign the way the intercooler mounts to prevent it from happening again?

Definately hard on parts . I havnt seen to many that can break as much crap as I do . Really suprised I have never snapped a crank myself . This is the second cooler in 5 years , not to bad really . Same crack , same place . This is from the intercooler tube jerking on the tank on hard hits side to side . Bad design , and your right I should find a fix , but I dont see one . Really tight cordinance in there . Not to bad for the abuse I give it . This usually happens after a week trip mobbing the truck in the dunes , I have an idea of when it happend . I dont think I will change anything and just add a new one . I thought about some solution , but I dont see any other than a really big , nice custom aluminum one . That would be cool . nobody makes one for this chassis I know of . Aluminum one might break easier than the plastic one too . Who knows . If I could drive like normal human this might not be such a problem .

See what showing off gets you . :rofl: Sand Drags at glamis is where I think it happend .

Did the plastic crack? I alway's thought that was a very poor decision to put plastic sides on the intercoolers due to the heat cycles. Seems to make them brittle and crack from vibration.

Yes the plastic tank cracked about 1/8" from tank to radiator seam . I agree on the brittle looking . It has been getting worse and worse as it has had hot air passing though the crack . The way chevy put the intercooler tube to it on driverside , it drops down under steering and when you rock the chassis is jerks the end of the tank back and forth really hard . Suprised I havent broke more of these .

Biggest issue really has been the turbo cranking vane position to compensate . I just got back form a 700 mile round trip towing a huge monster truck to vegas and back . Understandable now why egts have been up and power and shifting have all been really wierd . Truck has been really confused . Also might get rid of the weird injection knock . Maybe I have been overfuelling with the air it thinks it is getting .

Take off and kinda dead and slaggin and then a huge surge of power . Dont think I hurt anything , but definately shortened the turbos life some I would imagine .

Found a smokin price on a new one , but already have the intercooler with a different guy trying to get it fixed and no way to get ahold of him .

I found one right around the corner from me at Toms Truck Center for $402.00 bucks and could be back in business in about 2 hours . It sucks when you put out the feelers and find it and have to wait on somebodt else to call you . Im one of those impatient types . I have a feeling I should just buy it now but I dont want to screw over my other guy .

Grrrrrrrrrrrr ................


The best fix for all this I see , would be to mount a couple really small shocks on front clip assembly to take some of the rock out of the rubber mounted front clip on the truck . I actually might try looking into something like this . The whole front clip assembly on these truck is mounted on 2 rubber motor mounts and lets the whole front clip rock side to side bad . When I say whole front clip I mean the radiator , intercooler , trans cooler , ac / condenser , hood and all the stuff is all on a frame that is mounted on 2 rubber pin mounts the let the whole front end move seperately from the truck . Well guess what that does ? Makes the intercooler tubes mounted to the engine that doesnt move get jerked on like crazy every time the truck takes any hits side to side and ripped the tank and cracks it . Definately not suprised these break by the way they designed it .

Dont think they ever thought anybody would be doing the things I do . It actually has held up well if you look at how they did it .

Johnny

 

[duramaximizer]

If you want a custom one made, I think I can hook you up with one, or a guy that will make you one. Let me know.

 

[Gasuout]

If you want a custom one made, I think I can hook you up with one, or a guy that will make you one. Let me know.

Im waiting on the broken one to get a tank on it and found a new one local . I seriously would like to get a aftermarket cooler made in the near future .

I cant have the truck down like this . Losing a few tows already today for the offroad show local here . Would have paid for the second cooler .

I almost went and bought the one I found , but I will wait till morning .

Thanks for the offer , what do you think something like this would take to get done . Me sending the stock one to them to copy . What do you think something like this would cost .

 

[LBZrcks]

See what showing off gets you . :rofl: Sand Drags at glamis is where I think it happend .


Johnny

Man that was an expensive pass, broken diff, intercooler.....

 

[Gasuout]

Not really . It is all part of the fun . I call it 4 wheels parts having fun . You were in the truck for 5 passes just that day . There were at least 30 other passes down the drags that trip out . I was out there the whole week before you came up .

Many hits worse that that clobber we did that one pass .

The twisting up the truck in the dunes probably jerks the intercooled pretty bad too .