I have a 2004 f-350 4x4 with the 6.0 Diesel. I was driving and went to pass someone, when I hit the gas I heard a loud bang. Truck was still running good just lost power and blowing black smoke. Luckily I wasnt to far from home.

Got under the hood and the Rubber sleeve to the inter cooler blew off.
Put it back on and took for test drive. It was blowing black smoke, got on a straight away and gave it gas and intercooler sleeve blew off again.

Ive only had this truck 6 months. It has about 105,000 miles. The only Mod is the straight pipe exhaust.

 

Was your straight pipe mod done recently? The sleeves blowing off is pretty typical after a pipe mod.
Mine blew off the hot side almost immediately. I tightened it about 10lbs past the factory torque Then the other side blew off. Did the same too it. No problems after that Even did a 1500 mile round trip from ATLANTA to FAIRFAX, Va pulling 7k @ 70-80mph.

keep in mind that larger pipes allow more flow. (which is the goal) and in turn allows higher volume. Creating more pressure.
pull the sleeves, wipe both surfaces clean, reattach and torque around 10 lbs past factory spec. Dont over do it or your will split the sleeve.

 

Higher volume does not create more pressure. Large boost tubes will lower pressure, you can ask anyone who uses them, spool up is slower. Volume is good though. Boost is just a measurement of restriction though, it confuses everyone.

Clean the boots up really well, and use some hairspray on them, then put them back on.

 

the straight pipe is the stock pipe size. I took off the muffler and hacked off the Cat, put an elbow on to kick it out the side. Anyway, I did this right after I bought it (about 6 months ago). Before this happened I never had black smoke come out like it is now.

Could the veins in the turbo cause this problem? Sounds like the turbos go bad on these trucks pretty often.

 

when the boot comes off it will belch alot of smoke because of no boost pressure. You will also see more smoke then you are used to just because you don't have the cat on there to help burn off the excess fuel and soot

 

Thanks guys for the good info

 

what this guy said, you can use it liberally and it will ease them slipping on to the pipe / intercooler and when it dries it will help eliminate them popping off as long as you torque them down enough.

also using constant torque clamps can help too.