I'm sure this topic is old news for some of ya, but for those in the blind-
The plastic Cold side intercooler pipe going up to the turbo has a tendency to fail when it gets old and brittle from the engine heat.
Mine let go two weeks ago at 103,000 miles while towing my fifth wheel through the Kerrville hills. I heard the noise then the truck downshifted through the gears to first.
I was luckily 2 miles from the rest area and able to limp in there via a duct tape band aid job.
Once there I dropped the trailer and limped it back to the ford dealer in Kerrville and was able to buy the part for $169.
(its $110ish on ebay
)
They told me they keep seven or so in stock since they sell quite a few of them.
I slapped it on in under 15 minutes and was back on the road (just the necessary part, not the full 2' section they sell you as one unit- the bolt on intercooler portion was to hard to get to without more extensions- I'll replace that section later)
I know personally of one other person this has happened to under a load and there is a thread on powerstroke.org asking "where you were when your intercooler pipe failed"- so this is a somewhat common occurrence.
My PSA is this- if your 6.7 ford is at ~100k+ on mileage and you plan on loading it down anytime soon you might consider replacing this part
pre-failure or at least have a better understanding of what the noise you heard under the hood was when it goes "Poof" and walks your gears down to first.
There are aftermarket metal jobs out there for $350-500, or you could just replace the factory one for ~$110 when it gets some age on it (if you aren't buying it through the dealer ) .
Luckily mine failed on a Weekday, if not I'd have been stuck or had to pull some more redneck ingenuity out of the hat. I read of one guy who patched his with a rubber hose and has you to replace it months later.
Oh and BTW, this was the first issue with this truck ever- never been in the shop for any repair besides one Co sensor that was replaced under warranty and the somewhat mandatory periodic coolant checks.
I have replaced the worn out body bushings and shocks myself.
Here are the pics to show you what I'm referring to-
Broken Piece-
The zip tie is not OEM.
Where it is under the hood-
The plastic Cold side intercooler pipe going up to the turbo has a tendency to fail when it gets old and brittle from the engine heat.
Mine let go two weeks ago at 103,000 miles while towing my fifth wheel through the Kerrville hills. I heard the noise then the truck downshifted through the gears to first.
I was luckily 2 miles from the rest area and able to limp in there via a duct tape band aid job.
Once there I dropped the trailer and limped it back to the ford dealer in Kerrville and was able to buy the part for $169.
(its $110ish on ebay
) They told me they keep seven or so in stock since they sell quite a few of them.
I slapped it on in under 15 minutes and was back on the road (just the necessary part, not the full 2' section they sell you as one unit- the bolt on intercooler portion was to hard to get to without more extensions- I'll replace that section later)
I know personally of one other person this has happened to under a load and there is a thread on powerstroke.org asking "where you were when your intercooler pipe failed"- so this is a somewhat common occurrence.
My PSA is this- if your 6.7 ford is at ~100k+ on mileage and you plan on loading it down anytime soon you might consider replacing this part
pre-failure or at least have a better understanding of what the noise you heard under the hood was when it goes "Poof" and walks your gears down to first.
There are aftermarket metal jobs out there for $350-500, or you could just replace the factory one for ~$110 when it gets some age on it (if you aren't buying it through the dealer ) .
Luckily mine failed on a Weekday, if not I'd have been stuck or had to pull some more redneck ingenuity out of the hat. I read of one guy who patched his with a rubber hose and has you to replace it months later.
Oh and BTW, this was the first issue with this truck ever- never been in the shop for any repair besides one Co sensor that was replaced under warranty and the somewhat mandatory periodic coolant checks.
I have replaced the worn out body bushings and shocks myself.
Here are the pics to show you what I'm referring to-
Broken Piece-
The zip tie is not OEM.
Where it is under the hood-
, the hose clamp does sound like a good Idea. 
.
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