A number of people have repaired their ICs with JB Weld.

How long does this repair seem to last?

Also, is it possible to remove the IC to repair it without taking the nose off the vehicle?

Thanks!

DOC

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2005 KJ CRD Ltd Detroit TrueTrac Bilsteins G2 GDE "HOT" ECU GDE TCM "Tow Tune" "euro" TC SEGR Weeks Elbow New HG at 130K ARPs Clean CAT aFe Filter Magnaflow Exhaust EHM Cumminos In-Tank Lift Pump Hayden Fan Clutch Nylon Fan VH Enabled with GDE lower shutoff point Recalibrated Temp Gauge Tekonsha Prodigy Sears P-1 ZDDP

I don't think there is any way to get the cooler out without taking off the nose of the vehicle.

My JB repair only lasted about 5000mi. It was in the upper passenger corner near where the air inlet is, right where the tubes meet the end tank. I took the cooler out, degreased the area, cleaned it with brake cleaner and let it dry well. Then I took the cooler and set it on the passenger end, and basically mixed a bunch of JB and let it flow in and around the tubes in the leaky area. It probably set up about 1/8" thick for a good 8" length of that end tank.

Now I can see the telltale oil stains in the same area from blowby leaking out under pressure. I just don't think that JB can take the heat cycling. I haven't pressure tested it again to see how bad the leak actually is.

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05CRD: GDE Hot ECU & TCM tunes, Provent, Cat filter, Facet lift pump, TransGo kit, Florida TC, Samcos, stainless brake lines, HDS thermostat, Renegade light bar,
Bilstein adjustables, Al's Gen 4.5 Arms, 235/85-16 Duratracs, DTT rear, Elocker front, EVIC+TPMS, Turbo timer, McNally pillar gauges, Weeks Stage II kit.

CATCRD,

Can you guesstimate how much peak boost you may be losing?

Thanks again,

DC

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2005 KJ CRD Ltd Detroit TrueTrac Bilsteins G2 GDE "HOT" ECU GDE TCM "Tow Tune" "euro" TC SEGR Weeks Elbow New HG at 130K ARPs Clean CAT aFe Filter Magnaflow Exhaust EHM Cumminos In-Tank Lift Pump Hayden Fan Clutch Nylon Fan VH Enabled with GDE lower shutoff point Recalibrated Temp Gauge Tekonsha Prodigy Sears P-1 ZDDP

Probably less than a psi. At this low level of leakage it's not much of a power drain. Slow intercooler leaks can rob mpg though. Again, it's probably only a fraction of a mpg.

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05CRD: GDE Hot ECU & TCM tunes, Provent, Cat filter, Facet lift pump, TransGo kit, Florida TC, Samcos, stainless brake lines, HDS thermostat, Renegade light bar,
Bilstein adjustables, Al's Gen 4.5 Arms, 235/85-16 Duratracs, DTT rear, Elocker front, EVIC+TPMS, Turbo timer, McNally pillar gauges, Weeks Stage II kit.