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Intercooler Pipe Chaffing 
By Donald Ward aka ProBear

Most of the 99 and up PSDs have some sort of chaffing on the intercooler pipes. From what I’ve seen, this can and will vary with the mileage. 

These photos show the wear on my truck at 108,000 miles. I have two areas that IMHO were quite severe. If you are under the 3-year/36,000 mile warranty, the dealer at no charge will fix this item. If not, you will want to tie off the offending wiring harness and patch the area with filler. The worst wear on my truck was on the passenger side intercooler pipes; although a few people have reported wear on the underside of the driver’s side intercooler pipe. (The newer trucks have insulation on the driver’s side pipe and are not quite as prone to wear on this side.)