Some trucks may exhibit oil leakage from the hot side intercooler hoses. If one of the hot side intercooler hoses blow off it will cause the truck to exhibit a low power/low boost condition. Hot side intercooler tubes are no longer available as an assembly. Use the following parts as needed to service the condition:
Short upper hose, equal length elbow: 5C3Z-6C640-AA; metal tube: single alternator 3C3Z-6K769-DA or dual alternator 3C3Z-6K769-CA.
Long upper hose, unequal length elbow: 5C3Z-6C640-BA; metal tube: single alternator 5C3Z-6K769-AA or dual alternator 5C3Z-6K769-BA.
Use this hose and tube combination if the hose blows off
Clamps: upper hose 6C2Z-6K786-AA; lower hose to tube 6C3Z-6K786-CA; lower hose to intercooler 1C3Z-6K786-DA.
Lower hose, all: YC3Z-6C640-KA.
Clean the hose mating surfaces to ensure the hoses will stay in place. Seat the hoses completely onto their mounting surfaces before tightening the clamps to 9 ft/lbs. Test drive the truck while monitoring the boost pressures, which should be 22-25 PSI. An overboost condition will cause the hose to blow off.
TSB 05-13-5.
On 2004/05 trucks that exhibit the cold side hose/pipe blowing off at the intake manifold, replace the plastic tube with part #6C3Z-6C640-AA as in recall 05B29 (trucks built from 12-15-03 to 4-1-04), or repair as in TSB # 05-22-3 (trucks built from 4-1-05). Clean the intercooler and intake flange with brake parts cleaner. Seat the hose/pipe onto the intake manifold and torque the clamp to 9 ft/lbs (12 NM). Broadcast Message 1329, TSB 04-20-9, TSB 05-22-3.