1994-2002 Ford 7.3L Powerstroke Intercoolers & Piping

Intercooler and piping on the 1994-2002 Ford 7.3L Powerstroke

On the 1999-2003 Super Duty, compressed air leaves the turbo through the hot-side pipe and boots, passes through the air-to-air intercooler, and returns through the cold side to the Y-pipe and the two plenums. Ford built the intercooler as a tube-and-fin core with plastic end tanks and joined the piping with rubber boots on spring clamps. Late-1999 trucks also got the wastegated GTP38 turbo, and its 5-bolt compressor housing dictates the cold-side boot, which is why most boot kits start at 1999.5. The 1994-1997 OBS trucks are non-intercooled from the factory, so this collection is mostly Super Duty hardware. The crankcase ventilation also vents into the intake, so these boots carry oil mist as well as boost.

What fails and why

• Boots. Oil mist from the crankcase ventilation deteriorates the boots until one blows off. Low boost, oil residue at the joints, sluggish response and black smoke follow, and towing makes it worse. Tuned trucks see it sooner.
• Spring clamps. The factory clamps distort and loosen with age, and a loose clamp is a boost leak.
• End tanks. The plastic tanks on the factory intercooler can rupture under elevated boost, usually on tuned trucks or where the plastic is old. Expect sudden boost loss, a hiss and a crack you can see at the tank.

Whatever the symptom, pressure-test the charge system when boost is low before you replace the turbo. A boot, a clamp or a tank is a much smaller job.

Stock replacement vs. upgrade

For a stock truck, the CSF 6029 OEM+ replacement intercooler and the Mishimoto factory-fit boot kit restore the original layout. Replacement intercoolers generally trade the factory tube-and-fin core and plastic tanks for a bar-and-plate core with cast aluminum tanks, which matters if your tanks have already cracked. If you tow heavy or run a tune, look at the upgrade cores: the CSF 7107 heavy duty intercooler, the Mishimoto intercooler and pipe kit, the No Limit Fabrication 73IC, or the Banks 25973 intercooler upgrade. Mandrel-bent 3 in charge pipes replace the factory tubing for consistent flow. For the joints, the S&B 83-2011 kit uses 4-ply aramid-reinforced hot and cold side boots, and the BD Diesel 1047030 kit pairs new charge-air hoses with new clamps.

What we carry

• Mishimoto: an intercooler, an intercooler and pipe kit, a pipe and boot kit, and a factory-fit boot kit for 1999.5-2003.
• CSF: the 6029 OEM+ replacement intercooler and the 7107 heavy duty intercooler.
• Banks Power: the 25970 intercooler upgrade for 1994-1997 and the 25973 for 1999.5-2003.
• No Limit Fabrication: the 73IC air-to-air intercooler.
• PPE: a silicone hose coupling for 2001-2003 and a 3 in silicone hump coupler.
• S&B: the 83-2011 hot and cold side boot kit.
• BD Diesel: the 1047030 intercooler hose and clamp kit.

For the rest of the intake, browse our diesel intakes, or go back to the Powerstroke hub.

Fitment notes

Most of this collection is Super Duty hardware. Some parts are listed 1999-2003, but the S&B and Mishimoto factory-fit boot kits, the BD 1047030 and the Banks 25973 are listed 1999.5-2003, because trucks built before December 1998 have a different intake system and the late-1999 GTP38 housing changes the cold-side boot. Check your build date before you order. OBS owners: your truck has no factory intercooler, and the Banks 25970 intercooler upgrade is listed for 1994-1997 trucks. The PPE 315900100 coupling is listed for 2001-2003 only. The 7.3L ran into early 2003, so confirm the engine on any 2003 by VIN.

Frequently asked questions

Should I replace my intercooler or just the boots?

Find the leak first with a pressure test. If a boot or clamp is leaking, replace the boots and clamps. If a plastic end tank is cracked, the intercooler has to go, and a replacement with cast aluminum tanks takes the plastic out of the equation.

Can I add an intercooler to a 1994-1997 7.3L?

The OBS trucks were not intercooled from the factory. Banks Power lists its 25970 intercooler upgrade for 1994-1997 Powerstroke trucks. Call us before ordering so we can confirm it fits your truck.

Why does my 7.3L lose boost when towing?

Boost leaks get worse under load. Oily, deteriorated boots and loose spring clamps are the usual cause, and on 1999-2003 trucks a cracked intercooler end tank brings sudden boost loss with a hiss. Pressure-test before you condemn the turbo.

Do I need new clamps with new boots?

Plan on it. The factory spring clamps distort and loosen with age. The BD Diesel 1047030 kit pairs hoses and clamps for 1999.5-2003 trucks, and the S&B 83-2011 kit covers the hot and cold side boots.

Not sure what fits? Call the shop at the number in the header, or use the fitment checker on any product page. We install everything we sell.