I have stock hoses and intercoolers but I had this problem happen as well a few times after I changed my spark plugs. It turned out that my clip was bent just a tad so that one of the little "ears" on the boost hose would not securely lock into place so even though I would hear it click in, it was only really secured on one side. After a few hard pulls it would eventually pop out.

To see if this might be your problem, click the hose into place and then tug on it while wiggling it a bit. there should be no movement of the hose at the intercooler. For me I noticed one side was moving down just a hair out of the intercooler. I had to bend the clip a bit to get it to sit right and secure the hose but it worked.

Hope you get it fixed.

 

lol I am not going to drop $3k on new intercoolers just because a hose came off a couple times

If I drop $3k on anything its going to be an e85 fuel system!

The IATs on the 997.2 RS intercoolers are insane...especially for $1k for the pair. I traded my AP 3.5 inch with metal endtanks for these and my IATs are much better...after each pull i am back to ambient temps so quickly

 

Thanks for the help...I will give that a try. That metal piece has been through a lot of **** (my driving plus 4 hours of trying to get it back on lol)

 

Just saying... This is a market I've put PLENTY of money AND time in. We did our own work up until the BL kit/motor and even still we do any misc. work in the garage on jack stands like we did back in April of 2008 when I started makeing 650+rwhp

If I had people local that could have given me more help from the start it would have saved a LOT of money and time. I came from the LSx world prior and did a lot of R&D on my own car. It's not fun trying stuff over and over to get a good result.

 

just wondering. everyone refers to these intercoolers as gt2rs are they the same as the 997.2 turbo intercoolers? i cant find the part numbers for the gt2rs. thanks

 

Make sure that the 2 triangular ridges (circled in red) are not rounded at the top and both go straight down on the back side. This is where the metal tabs grab/click so if there's any distortion on these ridges you can lose the hose.

 

I checked the hose and there is some wear on those metal pieces, but not enough to matter (IMO).

I am missing the rubber piece though that goes over the boost hose, so I am SOL anyway.

I don't think anyone sells just one lower boost hose.

 

do you still have your stock ones? wonder if they can be trimmed to fit your turbos... the stock lowers typically stay on the best in my experience.

 

That to me looks like a standard rubber O-ring (although I've never worked on these cars). If that's the case you can easily pick one up.

 

its the clips most likely..go to the dealer and buy new clips....plus its the cheapest fix so start there .Had the same problem with a coolant hose on my car and i changed the clips.Never had the problem again

 

Plastic gives.... especially when sticking in a after market flange.... leak arise in many cases, heck ask Samas a 6 speed member how fast I found his leaks ... although he thought the new after market hoses were secure... all I had to do is pressurize and move the hose a little... hissing and pissing all over... take the car to a shop that know show to pressure test... have them install the hose and see what its doing under boost...
Then you will see that I was right...

 

Marek, you know I am trying to be more of a DIYer

I think I need a new clip and also I really need to adjust the hose a bit because I have to push the hose at a sharp angel very hard to get it to lock.

 

just have your mechanic look at it... Im serious... your going to screw it up.. the oring rips.. you dont even know... and there a leak... get some O Rings and clips and go get it done the right way.. aways put some lubricant on the flange so it goes in soother... not when its dry

 

I actually started having this issue as well. My lower driver side hose keeps blowing out and I am using stock hoses with the GT2RS intercoolers. It almost looks like the C clamp has a little side to side movement and doesnt full "grip" one of the tabs. I will look into it more tonight and see what i can come up with. Getting annoyed with this...

 

Thanks!

I need to find a new lower boost hose seal or just a new lower boost hose.