The Big Hoss bundle LargeMarge mentioned includes the Techni-Cooler which has the larger openings in/out of the "charge cooler", I almost bought one for mine. I haven't seen the nee to redirect the CCV either, just passing on options.

I've maxed out my 35psi gauge a few times, running the stock OEM Blue boots coming up on 100k miles and the CCV is still in the stock location. I believe Ford did update to a newer boot style after 04ish. Either way, at that point it's time to replace them like you said.

When you say you replaced the tube, I'm assuming you mean the boots? They should NOT be blowing off like this. You are no where near boot blowing power. If the problem persists, maybe try a good set of boots, like the one's dieselsite.com sells.

As far as the "issue" you've posted about... yeah, a lot of people have heard about this. It's completely unrelated to your boot blowing though. Are you pushing coolant out the degas cap? That's typically a blown EGR cooler or blown headgaskets.

Ahh, good catch Karl. Overlooked the part where he said he had the intercooler too. If anything the larger intercooler and piping will LOWER boost numbers though (not a bad thing). Boost is just a measurement of restriction anyways, typically when flow is opened up or a larger volume is created, overall boost will drop a bit.

well thats a bummer "This boot will not fit van applications or Banks Intercooler systems" Thats from Dieselsite.com

But thats what everyone says, "that it shouldent be blowing off" But its been doing it for years, new boots and all. Both ford, and banks ones. Thats why I had to come in here. You are my only hope. The hose from dieselsite, kinda looks like a radiator hose. Is that material oil resistant, and if so can I make a custom one? Do you think it would hold better?
Another worry I have is that the truck IS overboosting some how and it keeps blowing the weak spot instead of blowing something in the engine. People were taking about the veins getting stuck somehow. I live in california so it sounds like I cant get rid of the egr. Its just very frustrating.

You can take the factory EGR cooler off and weld freeze plugs in both ends of it and reinstall. It costs almost nothing to do and the appearance of the EGR cooler is still there, without the actual functionality! :tu:

As for the boots, no they're not radiator hose, that would most likely blow to shreds. The boots from dieselsite are really good boots. Even if your veins were sticking and you were overboosting, how high do you think you're going? Probably not enough to blow boots off... Your 06 has a factory boost gauge no? What is it hitting? There is something else going on here if it keeps pulling off. The only thing I can think of right now (sort of a long shot) is that the new banks intercooler perhaps isn't allowing the factory intercooler tube that attahces to the turbo to sit in the correct position and is throwing the alignment of that boot off a little, making it much easier to slip off of the turbo? I mean there are ways to fix a blowing boot, just depends how creative you want to get and how much $ you want to spend. What's the reason for the Banks intercooler anyways? They're nice units from what I hear, but your power levels don't necessitate it.

Let me see if I can dig up some pictures of some of the boot clamp setups I'm thinking of.

Try "Hairspray."

Currently it's all stock, still blows off. It hapends when it a constant boost on the gauge. About 25-30 psi. But like I said before I only tow a couple times a year when it happens.

Not sure if it's related but I get alot of fumes in the cab if I'm not running recirculated air. Just coming to a stop with the windows down I get a rush of fumes. Very stinky! I drive a 550 for work and it dosent smell at all.

Smell like raw fuel or burnt diesel...?

I peg my 35psi gauge on my race tunes, my boots have never blown off. If it keeps repeating I'd say new boots are in order.

More like stinky exhaust, to the point of coughing.

Nobody has mentioned anything about the clamps backing off, so, I will.

I took my 06 to the dealer for a glow plug controller failure, which they replaced under warranty. On the way home from the dealer I heard a loud POW! and when I got home I found that the turbo boost tube popped off.

I tried tightening the clamps and this seemed to work for a few days, but then POW! it happened again. I eventually figured out that the aviation nuts on the clamps were backing off. They have plastic inserts to prevent them from coming loose, but after tightening and re-tightening a few times the don't hold like they're supposed to.
So here is my solution. Put an extra nut on each of the clamps and tighten them down against the aviation nuts. We used to call these jamb nuts, but, you get the idea.
I haven't had a single problem with mine since I did this. And I assure you mine are just as oily as yours are.

Weird symptoms call for weird suggestions. What if the turbo was loose, or the pedestal cracked/broken? It could still make the boost, but it could also flop around. This flopping around could not only pull the boost tube off (both OEM and Banks), but could have cracked the exhaust leading to the exhaust leak. Probably unlikely, but you never know.

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My Banks Techni-Cooler (part of the Big Hoss Bundle) uses a spring under the nut on their hose clamps. The springs work pretty good because on my elbow I have one with nylon insert and one without.