I posted yesterday about my 2004 6.0L having poor acceleration. I found the coupler hose on the turbo outlet busted. It had a 1 inch tear in it. I ordered a new hose. One of the guys at work had an old hose and loaned it to me to see if my acceleration improved. I pushed the accelerator to the floor and my truck took off. As the boost came up you could feel a huge difference. After about 5 seconds the pipe that goes from the turbo outlet to the intercooler blew off. It keeps blowing off where the metal pipe goes into the rubber boot down on the inlet of the intercooler. I have tried several times and it keeps blowing off. I have tightened the clamps very snug. Is it possible I have a blockage in the intercooler? I was thinking that high pressure caused by a blockage could have been the cause for the blown upper attachment hose. Is there a trick to attaching these hoses? What controls the pressure of the boost and would a high boost pressure be detected by the control module giving me a code or CEL? Any help would be greatly appreciated.
Also, should I have ordered the hose from Ford or is there a better hose that you may recommend?
Thanks this site is awesome.

 

Ford hoses are OK, dieselsite.com sells some nice upgraded ones, but they're more $$ too.

Take all of the seating surfaces (inside of boot) and the tubing and clean it really well, they should be covered in oil thanks to the crankcase venting into the intake in front of the turbo... clean it well, then spray some hairspray on the surfaces, then reattach. Should be good to go. This is not uncommon. Once they're on/off a few times and get oiled up they pop off real easy. The key is to clean them really well and try the hairspray trick.

Glad it was an easy fix for you though, boots are common on higher mileage 6.0's. The earlier ones had different boots too, I believe Ford released "upgraded" ones.

 

Thanks. I was worried that I had a pressure blockage. Good to know that this is fairly normal. Thanks again.

 

Yea it is common i just had to put my 2nd set of factory boots on my truck and like mdub707 said dieselsite.com sells the best replacement boots for our trucks that is what i am going to order.