I have had the same problem with the front cooling duct falling off of the engine. The plastic colapses under the strain of the clamp pressure, developing a taper, and pushing itself out.
Here is the fix.

Remove the duct. It is easier than it looks, just one bolt under the front plastic and up near the radiator that has to be removed. Then, go to your local auto parts store or exhaust shop and get a 2 inch outside diameter piece of exhaust pipe about 1/2" long. Grind any burrs off of the pipe.
That pipe is going to fit inside the duct where it clamps to the front of the engine. It is a tight fit, but it's easier if you have a propane torch to carefully heat up the plastic to stretch it a little.
Slip the pipe inside so it is flush with the end of the duct. Then, take some coarse sandpaper and roughen up the area of the duct that is covered by the rubber boot/clamp assembly.
Install the duct, and don't be afraid to clamp that baby down tight.
No more problems.

 

I had the same problem and replaced the factory rubber connector with a piece of radiator hose a little bit longer so that i could get some good american radiator hose clamps on both ends. No leaks yet but i check the hoses often.

 

hey, I thought those were good 'ol Canadian hoser clamps, eh. [img]i/expressions/face-icon-small-wink.gif[/img][img]i/expressions/face-icon-small-smile.gif[/img] actually, if we both look really close on the clamp, I'm sure it will say made in China. But i also used the wider band style clamp.