Intercooler pipe/hose failure

MotoXXX

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Has anyone seen this issue before? If so, what was the cause of the failure? I was traveling home from deer camp Friday and it blew apart. I zip-tied it together and made it about 2 miles and it blew apart again. I found a hose clamp in my tool bag, put that on tightened it down with small channel locks. I cleared the codes with my scan tool, and went about 30 miles and the codes came back and it blew apart again. I pulled off the side of the interstate and called AAA. I had the truck and my 30' toyhauler both towed to the nearest town. It is sitting at the dealership waiting on a new pipe/hose. Something is causing an overboost condition. Apparently GMC has this as the weak point intentionally in the case of an overboost condition. 2023 with 29,000 miles and zero previous issues.
 

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Well the dealership called me today and said the intercooler pipe/hose connection must have just failed on its own with nothing else causing it. They replaced the pipe/hose assembly, cleared the codes, performed a manual regen and drove the truck with no issues. I hope they're right! Has anyone else heard of this happening like this? They told me they have seen 3 or 4 in their shop like this.
 

Aren't those some of the parts being called out by several expert mechanics?

Banks Engineering
Dave's auto
Westcott Designs
...
 

I don't know but it wouldn't surprise me! It seems they want that connection to be the weak point of the system for protection in the case of an overboost condition. Just my thought.
 

Well, I picked up the truck Saturday and made it about 50 miles and the CEL came on! Pulled over and scanned it and it was P2002 DPF efficiency low. Cleared it and only went 2 miles and it was back again. Drove another 40 miles and the same code came back there more times, clearing it every time with my scanner, except the last time because I'm taking it to the dealership I bought it from today. Apparently the dealership I had it towed into was wrong on the diagnosis so I called them. They said it was good when it left here....wtf?
 

It's becoming a "called out" issue so to say as time goes by. These intercooler boots/clamps are known to come apart. You're better off buying the banks version and saving yourself the headache.

I'm most definitely doing this upgrade this summer.

As far as your new dpf efficiency problem - How's your MAP sensor looking? Ever been replaced? Are you running a spacer? Id start looking at that for the root problem.
 

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It's becoming a "called out" issue so to say as time goes by. These intercooler boots/clamps are known to come apart. You're better off buying the banks version and saving yourself the headache.

I'm most definitely doing this upgrade this summer.

As far as your new dpf efficiency problem - How's your MAP sensor looking? Ever been replaced? Are you running a spacer? Id start looking at that for the root problem.
I would have no idea this is the first time it's been in the shop and it's under warranty so I'm not going to work on it
 

I would have no idea this is the first time it's been in the shop and it's under warranty so I'm not going to work on it

Its a super easy replacement. Those sensors are known to get clogged up with sut and cause havoc on your emission system. I personally run a banks spacer. If youve never replaced it chances are it's super gunked up and may be the root cause of your new code.
 

It's becoming a "called out" issue so to say as time goes by. These intercooler boots/clamps are known to come apart. You're better off buying the banks version and saving yourself the headache.

I'm most definitely doing this upgrade this summer.

As far as your new dpf efficiency problem - How's your MAP sensor looking? Ever been replaced? Are you running a spacer? Id start looking at that for the root problem.
I'm losing count of the # of things we need to watch out for failure. So far so good 🤞
 

I'm losing count of the # of things we need to watch out for failure. So far so good 🤞
There aren't that many issues with the Duramax. My only complaint is the stupid wax on GM frames.

The present Duramax "things to watch out for" aren't as serious or expensive as prominent failures in the competition - powerstroke (CP4) or Cummins (lifters, grid heater bolt).
 

There aren't that many issues with the Duramax. My only complaint is the stupid wax on GM frames.

The present Duramax "things to watch out for" aren't as serious or expensive as prominent failures in the competition - powerstroke (CP4) or Cummins (lifters, grid heater bolt).
Thats good to know. (y)
 

As with all the other trucks, the emission system is what's causing most of the problems. Long as you do your oil changes regularly, get diesel from reputable stations and maybe use additives and/or a VSE fuel system saver system and let your truck complete a Regen when it's time you'll be fine.

Problems start when people don't monitor their Regen and then turn their truck off mid Regen.
 

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