Factory Powerstroke intercooler/turbo boots take a beating from heat, oil vapor, boost pressure, clamp load, and just general use over the years. Eventually they swell, crack, soften, seep, or lose their grip at the connection point.

Riffraff Diesel’s intercooler boot upgrade lineup covers the common failure areas for the full line of 7.3, 6.0, and 6.4 Powerstrokes, including the Econoline vans.

CAC Boot Parts Links (more are available, most common listed below):

CAC Intercooler Single Boots - https://www.riffraffdiesel.com/cac-intercooler-single-boots/

Riffraff Diesel Plenum Y Boot Set (94-97) - https://www.riffraffdiesel.com/riffraff-diesel-plenum-y-boot-set-94-97/

94-97 Turbo Intake and Y Boot Kit - https://www.riffraffdiesel.com/riffraff-diesel-94-97-turbo-intake-and-y-boot-kit/

Complete CAC Intercooler Boot Kit 99-03 - https://www.riffraffdiesel.com/complete-cac-intercooler-boot-kit-99-03/

99-03 7.3 Upper Intake Manifold Boot Kit - https://www.riffraffdiesel.com/cac-intercooler-upper-intake-manifold-boot-kit/

6.0L Turbo Outlet Elbow CAC Boot 03-07 - https://www.riffraffdiesel.com/6-0l-turbo-outlet-elbow-cac-boot-03-07

Complete CAC Intercooler Boot Kit 08-10 - http://riffraffdiesel.com/complete-cac-intercooler-boot-kit-08-10/

 

CAC Intercooler/Turbo Boots

CAC (Cool Air Charge) boots seal the charge-air system between the turbo, intercooler, intake piping, and intake manifold. With age the factory boots can leak or fail altogether, causing the truck to lose boost and overall efficiency. High EGT, excessive smoke, and a loss of power are teh most common symptoms.

Riffraff offers complete CAC boot kits for 1994–2003 7.3L, 2003–2007 6.0L, and 2008–2010 6.4L Powerstroke trucks. Depending on application, these utelize reinforced Aramid construction, silicone outer layers, both ideal for high oil resistance and working pressures of up to up to 180 psi. 

 

Why silicone makes sense

Good silicone hoses are not just about color. They handle heat better, resist pressure and take the clamp load better, and they last longer than old factory rubber. Especially for CAC boots, the added strength helps keep boost where it's supposed to be. 

 

Fitment notes

7.3 CAC boots: Measure intercooler inlet and outlet size. Some years used multiple sizes.

6.0 CAC boots: Verify metal vs plastic CAC piping.

6.4 CAC boots: Replace tired clamps with the matching clamp kit.

Econoline hoses: Do not substitute F-Series truck hoses for van-specific boots.

 

Install Tips

Remove the old hose, clean every sealing surface (the old hairspray tip is not necessary, just make sure everything is clean), inspect the pipe bead for damage, install the new silicone hose fully seated, position the clamps squarely, tighten evenly, then heat-cycle or pressure-test the system and recheck every connection.

 

Smart add-ons

For CAC boots, add the matching intercooler boot clamp kit or individual stainless T-bolt clamps. Also, for 7.3's, the factory plenums are famous for their lack of structural integrity. Check out our Plenum Reinforcing Inserts to stop them from collapsing under load.

Parts Links:

RDP Plenum Reinforcing Inserts 94 - Early 99 - https://www.riffraffdiesel.com/rdp-plenum-reinforcing-inserts-94-early-99/

RDP Plenum Reinforcing Inserts 99.5-03 - https://www.riffraffdiesel.com/rdp-plenum-reinforcing-inserts-99-5-03/

Stainless Steel T-Bolt Boot Clamps - https://www.riffraffdiesel.com/stainless-steel-t-bolt-boot-clamp/

Intercooler Boot Complete Clamp Kit 7.3L 99-03 - https://www.riffraffdiesel.com/intercooler-boot-complete-clamp-kit-7-3l-99-03/

Intercooler Hot Side Boot Clamp Kit 6.0L - https://www.riffraffdiesel.com/intercooler-hot-side-boot-clamp-kit-6-0l/

Intercooler Boot Complete Clamp Kit 6.0L - https://www.riffraffdiesel.com/intercooler-boot-complete-clamp-kit-6-0l/

Intercooler Boot Complete Clamp Kit 6.4L - https://www.riffraffdiesel.com/intercooler-boot-complete-clamp-kit-6-4l/