2008-2010 Ford 6.4L Powerstroke Air Intake Parts

Air intake on the 2008-2010 Ford 6.4L Powerstroke

Air comes in through the factory airbox, which holds a Motorcraft FA-1886 filter and a filter minder. From there it feeds two BorgWarner turbos plumbed in series: a 65 mm fixed-geometry low-pressure turbo that hands off to a 52 mm variable-geometry high-pressure turbo. Hot, compressed air leaves the turbos through the hot-side boots, runs through the air-to-air intercooler, and comes back through the cold-side boots toward the intake. Along the way, exhaust from the EGR valve merges with the charge air; the valve opens at steady throttle when exhaust back pressure is higher than manifold pressure. Stock boost runs roughly 40 to 42 psi, and every boot, coupler and clamp in that path has to hold it. Ford says to change the air filter when the filter minder tells you to, not on a fixed mileage.

What fails and why

The documented weak point on this engine is the charge-air connections, not the intercooler core. Boots, couplers and clamps crack or blow off from heat and 40-psi boost, and the hot side, which takes the most heat cycles, usually goes first. It happens gradually. You will notice low boost, smoke, a sluggish throttle, a hiss under load, or a P0299 code. Here is the expensive part: a leak anywhere in the charge system gets misdiagnosed as turbo failure, so trucks with healthy turbos end up with boost complaints and a turbo quote. Banks markets its cast end tanks against the stock plastic end tanks, which it says can burst, with sudden boost loss and oily residue at the tank seam as the signs. Take that as a seller's pitch. The factory core itself is not the 6.4L's weak point; the connections are.

Stock replacement vs. upgrade

Before you buy an intercooler or a turbo, smoke-test the charge system. It finds the split boot or loose clamp that is costing you boost before you spend money on parts you may not need. If the boots are tired, factory-fit replacements put the system back the way Ford built it, and OEM-style sensors and gaskets do the same for the intake side. If you tow heavy, or you are already replacing hardware, an upgrade makes sense. The Banks 25984 intercooler adds cast end tanks, 14% more flow, over 5% more air density and over 1/2 psi more boost, and Banks lists it as 50-state compliant under CARB EO D-161-90. Heavy-duty and aftermarket intercoolers, hot pipes and cold-side kits replace the stock plumbing outright. On the intake side, an S&B washable-filter cold air intake is one of the documented replacements for the factory box. Whatever you choose, check the listing for a CARB EO number if the truck has to pass inspection.

What we carry

• Intercoolers and piping: Mishimoto factory-fit boots, boot kit, intercooler and pipe-and-boot kit; CSF OEM+ replacement and heavy-duty intercoolers; the Banks Power 25984 intercooler; No Limit Fabrication hot pipe, cold-side and air-to-air intercooler kits plus a lower hot-side connection boot.
• Couplers and clamps: a PPE 3-inch silicone hump coupler, an S&B 4-inch silicone coupler with clamps, and a BD Diesel intercooler hose and clamp kit and high-torque hose clamps.
• Intakes and filters: the S&B 75-5105 and No Limit 64CAI cold air intakes, the S&B KF-1051 replacement filter and WF-1022 filter wrap, the No Limit NLRF filter, the S&B Precision II cleaning and oil kit, and a Banks pre-filter wrap for Banks Ram-Air filters.
• Sensors and gaskets: Alliant Power MAF/IAT1, intake air temperature, ambient air temperature and MAP sensors; XDP MAP sensors; MAHLE intake manifold gasket sets and a throttle body mounting gasket.
• Emergency shutdown: BD Diesel Positive Air Shutdown valves and the E-PAS emergency engine shutdown.

Shopping intakes for another truck? See our intakes page.

Fitment notes

The intake, intercooler and boot kits here are built for the 2008-2010 6.4L only. For 2011 Ford launched an all-new Super Duty with the 6.7L, and 2010-and-earlier charge-air parts do not carry into it. Some sensors, gaskets and boots in this collection are listed for both the 6.0L and the 6.4L, and the Alliant ambient air sensor runs through 2014; read the year and engine range in each product title. F-450 and F-550 owners: Banks lists its intercooler as compatible with those trucks, but check every other listing for your model. When in doubt, verify by VIN. Everything else for this engine family is on our Power Stroke page.

Frequently asked questions

My 6.4L is down on boost. Is it the turbo?

Not necessarily. On this engine, leaks anywhere in the charge system get misdiagnosed as turbo failure. Low boost, smoke, a hiss under load and a P0299 code all fit a cracked or blown-off boot. Smoke-test the system before you price a turbo.

Which boots fail first on a 6.4L Powerstroke?

The hot side. Boots, couplers and clamps crack or blow off from heat and boost, and the hot-side joints see the most heat cycles. If one hot-side boot has split on a high-mile truck, inspect the rest while the truck is apart; the Mishimoto boot kit covers more than one joint.

Is the Banks intercooler emissions-legal?

Banks lists the 25984 intercooler as 50-state compliant under CARB EO D-161-90, with fitment for the F-250, F-350, F-450 and F-550. For any other intake or intercooler part, look for a CARB EO number on the product listing before you count on it being legal where you live.

How often should I change the air filter?

Ford says to change the factory Motorcraft FA-1886 when the filter minder on the airbox calls for it, not on a fixed interval. If you run a washable S&B element, the S&B Precision II kit is what you clean and re-oil it with.

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.