Cracked Turbo Hose Fix (ADAP09) FAQ for 2002-2007 Dodge Sprinter

What is the cracked turbo hose Fix ?
A. The cracked turbo hose fix, our ADAP06 is a billet aluminum adaptor that replaces the metal end on the intake side turbo hose found on the driver’s side on the 2.7 liter, 5 cyl. In-line Mercedes Benz turbo diesel engine found in 2002 up to2007 Dodge Sprinter Vans. Our Hose adapter has a nicely rounded end which resists hose cracking even in high temperatures, high vibration and high boost pressures. The Sprinter chassis is becoming increasingly popular with RVers and commercial users because of its great fuel economy and driver-friendly characteristics. However, the intake turbo hose with its flawed metal ends is causing the Sprinter chassis to suffer an inordinate amount of breakdowns.
Q. What exactly is this turbo hose end failure problem I have been hearing about on the Sprinter (tm) van chassis?
A. A typical turbo hose end failure happens under a period of maximum boost either climbing a hill or accelerating off a stop light with a load in the vehicle, although we know of failures where the vehicles have NOT been under a load and the hoses have still failed. The failure results from, in our opinion, an extremely poor design of the attach point between the rubber hose and the metal end “formed” onto the hose. In the process of sealing the rubber hose to the steel hose fitting, the hose is “machine pinched” into the metal fitting in a manner that sets the hose up for failure right from the start. (Be sure to see the PDF of our installation instructions for clear photos of the problem) The failure occurs on the driver’s side hose (the only hose on this engine with this fitting) due to constant expansion , contraction and flexing. Most Dodge Sprinter service departments are acutely aware of this problem, however until now, the only solution was to replace the entire hose assembly at a cost of around $120 to $140 just for the hose assembly, not counting labor. To avoid getting stuck on the road, we are recommending replacing this hose end with the ADAP06 to prevent the failure before it happens.
Q. What happens when the Sprinter turbo hose ends fail?
A. The boost sensor sends a low pressure signal to the engine's computer which “thinks” there has been a failure of the turbo and the vehicle immediately goes into "limp home" mode which results in a nearly total loss of ability to climb hills and a top speed on flat ground of about 35 to 40 mph. This usually results in having the vehicle towed in for repair, however this particular problem can start out with “partial failures” since the cracks sometimes start out very small and can put you in AND OUT of “limp home mode” several times before full failure or “blow out” of the hose puts you in limp home mode once and for all. This is not exactly a desirable feature in emergency medical service vehicles, armored vehicles, RVs and other commercial vehicles that cannot afford to become inoperable. It is especially troubling to RVers who use their vehicles to “get away from it all” only to find that after they are “away from it all” they are now hundreds of miles or hours away from help. In addition, the check engine light comes on. If our ADAP06 hose adapter is installed after a failure, the check engine light should go off after a few starting cycles. ( full warm up and cool down of the engine. )
Q. Can a turbo hose end failure make the vehicle unsafe?
A. We have spoken regularly with Sprinter RV and commercial vehicle owners who had this turbo hose end blow out, and barely avoided being rear-ended, since when the vehicle goes into limp home mode, there is no warning for driver approaching quickly from behind. Some of these customers had already installed our turbo resonator eliminators on their Sprinters and immediately called us to ask if this was a similar problem, since the end result seemed to be exactly the same.

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