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Recall in Review - Customer Satisfaction Program 05B29
June 10, 2005 The Left or cold side CAC (charge air cooler) tube on some 2004
F-Series and Excursion sport utility trucks equipped with a 6.0L Power Stroke Diesel engine may become loose
and could pop off of the intake elbow on the engine. If this happens, the engine will lose all turbo boost
and will suffer a severe lack of power. This will render most vehicles undriveable. The CAC tube is a black,
blow molded tube on the left side of the engine on most 2004 and 2005 model year trucks. Not all black CAC
tubes are affected by this program, however it is recommended that the tube and the clamps be inspected for
proper assembly and clamp tightness regularly on all trucks that have them.
 05B29 Program Facts
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2004 F-Series F250 though F550 Super Duty trucks and Excursion sport utility vehicles built from December
23, 2003 though March 31, 2004 are to have the cold side Charge Air Cooler (CAC) tube replaced with an
updated part.
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All of these vehicles are also affected by the Safety Recall 05S34 and should be performed together. A
road test will also be performed to verify any repairs and identify additional driveability concerns that
may exist.
The Technicians Perspective
Replacing the CAC tube is a simple procedure which requires only the air filter housing assembly be removed
from the truck to allow access to the tube and clamps. The black tube is removed and discarded and replaced
with a new steel tube with black rubber connector hoses and new clamps. The following Photographs show the
old and new parts.
Photo 1
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Photo 2
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This article is only to provide information. It is hoped that this review has clarified this Customer
Satisfaction Program in a simple and easy to understand presentation and that we clearly illustrated what the
technician does while performing this program. This is not intended to replace any official instructions,
authorization or documentation of any Ford Motor Company recall or program.
 FDDTS
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