Boost Leak!!!

[dodgeram2500]

i was towing my 10k trailer this weekend when my boost levels started to get barely above 15lbs. when i got home i checked for leaks from the turbo to the intake manifold with pressurized air and soapy water. 3 intercooler boots were torn, and the long plate under the heater grid was leaking like crazy! i only put about 15psi thru the intake syatem and it was leaking very bad. the truck was pulling great from denver, co to phoenix, az then all the sudden hardly any boost. any ideas on what could have caused this? im at a loss. the head was built no more than 10k miles ago. everything was good up till now? is that gasket easy to replace? who makes a good boot kit? would running the water inj. for a long time have much to do with it?

 

[Billysgoat]

It happens, the gasket is fairly straightforward to replace, just go to your local cummins dealer for an intake gasket. Bolt torque is only 17ftlbs or so if my memory serves me correct. You will have to pull all the injector lines, but that's the hardest part.

Boots can be had from about any parts house, not sure who makes some good aftermarket units, but if you are running under 60PSI of boost I don't really see where they are needed, stockers should hold just fine.

 

[Big Blue24]

Add some sort of silicone sealant or gasket maker to that new intake manifold plate gasket. I replaced mine a year ago and it is leaking again between 1-2 and 2-3 bolt spans where the gasket is bulging. I replaced mine with a new cummins gasket, it seems over 40 psi is what squeezes it out and causes the leak. I know silicone will set up and make it very difficult to remove the plate in the future but why would you ever need to remove that intake plate anyway?

 

[dodgeram2500]

i got a gasket from my local napa dealer. the gasket they gave me was a felt type gasket. the original one was steel... any harm in using the napa one or is the dealer the only way to go?