Strange Turbo Sound

[Chaps3500]

I am having a strange issue with my 2019 3500 6.7L Cummins HO. This past month I installed a Banks Monster Ram bundle with new intercooler tubes and air box. I have had a pedal monster for years and have been very happy. Installed all products and all seemed great at first. Truck ran well, but I was surprised I seemed to loose a bit a fuel economy. Regardless of that I had a very consistent and strong turbo whistle sound under acceleration (way more than stock which I was not disappointed by now having) but now after about 800 miles of driving, including last weekend 300 miles of towing my fifth wheel and using the exhaust brake, now out of the blue the other day under acceleration the whistle is not consistent and I am getting a strange fluttering whistling sound instead of a consistent whistle under acceleration. I checked all clamps and hoses are good reseated and tightened etc. No check engine light, performance seems fairly normal. Has anyone else out there experienced this either with or without the Banks Monster Ram installed? I greatly appreciate the input if you have any. I took videos and it can be heard easily. Just don’t know how to post it to the forum.

 

[AH64ID]

Is your boost fluctuating with the noise?

 

[Chaps3500]

Is your boost fluctuating with the noise?

At times it seems like the gauge wobbles but I’m just going off the instrument cluster so hard to say if it is truly accurate I guess.

 

[Ostracize]

Check the charge pipe coming out of the turbo for a hole worn in the top about 5in from the turbo.

 

[Chaps3500]

All good there. All brand new.

 

[AH64ID]

All good there. All brand new.

Doesn't mean there isn't a leak or loose hose.

 

[Chaps3500]

Doesn't mean there isn't a leak or loose hose.

Agreed but have already verified all of that is good is what I mean. Not leaking there. Have removed verified refitted and tightened all clamps on lines.

 

[N900WM]

I have had the same issue 3 times and in all cases, the noise was preceaded by a boot or clamp coming loose and rendering the truck inoperable with a trailer attatched and marginal without a trailer.
In fact, I am on a trip now and in addition to a boot/clamp coming loose again, the Banks cold air intake was so hot where it connects to the turbo, it became soft and collapsed under the pressure of the hose clamp creating a boost leak as well. I could literally mold the plastic with my thumbs!

On the side of the road for 4 hours in 110 degree heat trying to fix it only to loose a nut off an intercooler boot clamp in the ditch. Had to tow the truck and the trailer. The truck is now at the dealer having the stock tubes re-installed as well as the stock airbox.

I had completed a preflight inspection on all these parts before I left because I didnt want to have this happen a 3rd time. Everything was properly in place and snug. The difference this time was the heat...I've not towed this setup before now in any temps over 60 degrees F.