Ford 6.7 Intercooler Pipe Failure – Expensive to Fix?

An intercooler pipe is a vital component of the Ford 6.7 engine. It helps cool the air that has been compressed by the turbocharger before it enters the engine. This cooled air is denser and contains more oxygen, which can help increase power and efficiency.

Key features and my opinion about the engine

• Production years:2011-2016
• Average lifespan of 6.7 Power Stroke:240,000-270,000 miles
• Fuel supply type:Common Rail
• Power range:330-475 hp
• Fuel efficiency:average
• Engine block material:cast-iron
• Engine reliability score:medium
• The most common problems:turbo problems, cooling system issues, weak sensors, CP4 pump problems.

How the Intercooler Works

The intercooler pipe in the Ford 6.7 is made from aluminum material and is located between the turbocharger and the engine. It is connected to the turbocharger outlet via a hot side charge pipe and to the engine intake via a cold side charge pipe. Coolant from the engine cooling system circulates through the intercooler core to help keep it cool.

If your Ford 6.7 engine isn't performing as well as it should, or if you notice any strange noises coming from the turbocharger area, then it's possible that the intercooler pipe is damaged or has come loose. In this case, it's important to get the problem fixed as soon as possible to avoid any further damage to the engine.

Common Causes of Intercooler Pipe Failure in the Ford 6.7

According to owners of Ford vehicles equipped with the 6.7L engine who have experienced an intercooler pipe failure as well as mechanics familiar with the issue, the most common causes of the problem are the following:

1. Blown Intercooler Pipe

A blown intercooler pipe in a Ford 6.7 engine can cause many problems for the vehicle. The most common problem is decreased performance because the engine will not be able to properly cool itself and will therefore run less efficiently. Another problem that can occur is increased fuel consumption as the engine will have to work harder to maintain its temperature. In some cases, a blown intercooler pipe can also lead to engine damage if the engine overheats.

There are a few possible causes of a blown intercooler pipe. The most common cause is simply wear and tear on the pipe, which can occur over time due to the heat and stress of regular use. According to a number of owners, this problem tends to happen within the 100,000-mile mark of the vehicle.

Another is an accident or collision, which can damage the intercooler pipe and cause it to leak. Finally, a manufacturing defect can also lead to a blown intercooler pipe.

There are a few potential solutions to a blown intercooler pipe. The most obvious solution is to replace the damaged pipe with a new one. This can be done by a qualified mechanic or, in some cases, by the owner of the vehicle if they have the necessary skills and knowledge. Another solution is to patch the leaks in the pipe, which can temporarily fix the problem but will not be as effective as replacing the entire pipe. Lastly, in some instances, it may be possible to simply bypass the intercooler altogether, although this should only be done if absolutely necessary and only as a temporary remedy.

2. Clogged Intercooler Pipe

Intercooler pipes can become clogged for some reason. The most common is probably due to debris and dirt getting into the system and causing a blockage. This can happen if the air filter is not replaced regularly, or if the vehicle is driven in very dusty or dirty conditions.

Another cause of a clogged intercooler pipe is leaks in other parts of the cooling system. If coolant is leaking from the radiator, for example, it can get into the intercooler system and cause a blockage. This is why it's important to keep an eye on all fluid levels in your vehicle and to have any leaks repaired as soon as possible.

If your intercooler pipes are clogged, it can cause a number of problems for your vehicle. The most obvious is reduced performance and your engine may struggle at times, as the intercooler is not able to do its job properly. This can lead to reduced power and acceleration, and worse, the engine may even overheat.

Fortunately, cleaning or replacing clogged intercooler pipes is relatively straightforward. If the problem is due to debris and dirt, then simply flushing the system out with water, liquid solution, or pressurized air will usually suffice.

More serious blockages may require disassembling the intercooler system to clear them out manually. Leaks in the other parts of the cooling system should be repaired as soon as possible to prevent further damage, too.

3. Worn Intercooler Clamp

Intercooler clamps can become worn over time. This can affect the performance of your vehicle, as the clamps are responsible for holding the intercooler in place.

The symptoms of a worn intercooler clamp can include vibrating sounds coming from the engine bay, reduced engine performance, and a loss of power. If you experience these problems, it is important to have the clamps replaced as soon as possible.

There are several possible causes of this problem, and some potential solutions. One is simply age and wear and tear. Over time, the clamps can become loose, which can allow the intercooler to move around. This can lead to performance loss and even engine damage.

A substandard aftermarket intercooler can be the culprit also. Some aftermarket intercoolers are not compatible with the stock clamps, and can actually damage them.

The best solution for worn intercooler clamps is to replace them with new ones. You can get new clamps from your local Ford dealer or an aftermarket supplier. Be sure to get the right size and type of clamp for your vehicle to avoid compatibility issues.

If you have questions about replacing your intercooler clamps or any other car maintenance questions, be sure to consult an experienced mechanic. They will be able to help you find the right parts and provide guidance on how to properly install them.

4. Damaged Intercooler Turbo Hose Retaining Clip

The intercooler turbo hose retaining clip is responsible for holding the turbo hose in place. If it becomes damaged, it can result in a number of problems for your vehicle.

The most common is when the clip was not installed correctly in the first place. If this is the case, simply reinstalling the clip correctly should solve the problem.

Next, the clip may have been corroded or otherwise damaged over time. In this case, replacing the clip with a new one should solve the problem.

If you're still having problems with the clip, the turbo hose itself may be damaged. In this scenario, you'll need to replace the hose as well.

Intercooler Pipe Replacement Cost

The cost of parts replacement and labor to fix an intercooler pipe failure depends on the specific model year of your auto, the shop where you will take it, your location, and the complexity of the damage. However, a conservative estimate for the labor is between $158 and $199 in most cases. Meanwhile, an intercooler pipe replacement will only push you back by $209. For the other parts mentioned in the previous section, an intercooler turbo hose and clamp will only cost you around $20.

Compared to potential engine damage that may arise should you prolong the intercooler pipe issue, the overall price for the repair or replacement is definitely worth the investment.

Intercooler Pipe Upgrade Kit

There are ways to further improve the performance of your intercooler. The most popular so far is through the use of an upgrade kit.

In a nutshell, the kit replaces the stock intercooler pipes with larger ones that have fewer restrictions. This allows more air to flow through the system, which helps to improve power and efficiency. The kit also includes a new intercooler, which is designed to provide better cooling than the stock unit.

Overall, an intercooler pipe upgrade kit is a great way to improve the performance of your Ford 6.7 engine. The kit is relatively easy to install, and it can provide a significant boost in power and efficiency.

The kit includes instructions that walk you through the process step-by-step. You will need to remove the stock intercooler pipes and the intercooler from the engine, and then install the new pipes and intercooler.

It is important to note that the installation process can vary depending on the kit that you have chosen. Again, make sure to read the instructions carefully before beginning the installation process.

Once the installation is complete, you will notice a difference in the performance of your Ford 6.7 engine. Just remember to choose a reputable company that offers quality intercooler kits. With a little time and effort, you can enjoy the benefits of an intercooler pipe upgrade kit on your Ford 6.7 engine.

Conclusion

A Ford 6.7 intercooler pipe failure can be a serious issue for your vehicle. As shown here, if it's not addressed immediately, it could lead to engine damage or even a complete engine failure. So, if you notice any issues with your intercooler, make sure to have it checked out by a professional as soon as possible to prevent it from branching out into a more serious problem along the way.