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Call or Text (352) 722-5295Air intake on the 2015-2016 Ford 6.7L Powerstroke
The 6.7L Powerstroke is laid out backwards from older Ford diesels. The aluminum heads are reverse-flow, so the intake ports sit on the outside and the exhaust and turbo live in the valley. Outside air comes in through an enclosed factory airbox with a pre-filter and a main element, then feeds the turbo. For 2015 Ford dropped the 2011-2014 DualBoost turbo and fitted a larger Garrett GT3788V single variable-geometry turbo, part of the jump to 440 hp and 860 lb-ft. Compressed air leaves the turbo through the hot-side boost tube, gets cooled in an air-to-water charge-air cooler in the valley, and comes back through the cold-side tube to the intake. There is no front-mount air-to-air intercooler on this engine. The cooler runs on the secondary, low-temperature coolant loop, which it shares with the fuel cooler and the transmission cooler.
What fails and why
The weak link is plastic. Ford ran plastic boost tubes, roughly 2.34 inches on the hot side and 2.37 inches on the cold side. On 2011-2016 trucks the cold-side tube cracks and the hot-side tube can pull off the turbo outlet. Heat cycles and age cause it, and failures get reported under tow and at altitude. When it happens you hear a whistling boost leak, the truck loses power all at once, and you may see P0299, P1247 or P0402. A leak that goes unnoticed also loads the DPF with soot faster than normal. S&B's own product listing calls the factory cold-side pipe failure prone and warns it can burst and strand you.
The second item is maintenance, not failure. Ford calls for the air filter at 45,000 miles or as required, and trucks that work in dust need it checked more often. A restricted filter or soot in the airbox can show up as MAF-related codes.
Stock replacement vs. upgrade
For a filter that is simply due, stock is fine. The factory set on 2011-2016 trucks is a two-piece Motorcraft FA-1909 pre-filter and FA-1902 element. Boost tubes are a different story. Swapping a cracked plastic tube for another plastic tube puts the same part back on the truck. Aluminum intercooler pipe kits from S&B and Mishimoto, and steel tubes, are the documented replacements for the plastic pieces. On the intake side, the S&B 75-5104 cold air intake uses an enclosed box and is rated at 31.7 percent more airflow than stock with the oiled cotton filter (99.26 percent efficient) or 29.8 percent with the dry filter (99.66 percent). It carries CARB EO D-590-13 for the F-250 and F-350. For any intake-path part, look for an EO number that covers your truck if you live where emissions equipment gets inspected.
What we carry
Intercooler piping leads this collection: hot-side and cold-side pipes, boots and couplers from SPE Motorsport, S&B, Mishimoto, PPE, XDP, No Limit Fabrication, BD Diesel and Wehrli Custom Fabrication. Mishimoto and PPE also offer air-to-water intercooler kits for the valley core. Cold air intakes come from S&B, No Limit Fabrication, Banks Power and SPE, and PPE's Zilla intake manifold and turbo inlet kit is listed specifically for 2015-2016. Filters include S&B KF-series elements and filter wraps plus the MAHLE LX5224. Alliant Power and XDP cover the MAF, MAP, ambient air temperature and charge air temperature sensors, MAHLE supplies throttle body and intake manifold gaskets, and BD Diesel has positive air shutdown valves. Shopping across trucks? Browse all of our intakes.
Fitment notes
2015-2016 trucks are the last of the steel-body third-generation Super Duty, and many intake and boost-tube parts change for 2017 and newer trucks. Inside 2011-2016 most parts carry over despite the 2015 turbo change, but not all of them. S&B lists its 83-2003 hot-side pipe for 2011-2015 F-250 and F-350 only, and its 83-2004 hot-side pipe starts at 2016, so a 2015 and a 2016 can need different hot-side pipes from the same brand. The S&B 75-5104 EO covers the F-250 and F-350; F-450 and F-550 trucks have no EO on that part. Chassis cabs also run a different turbo (Garrett AVNT3276V) than the pickups. Read the years and models on each listing, and verify by VIN before you order.
Frequently asked questions
Why did my 2015 F-250 suddenly lose power and set P0299 while towing?
Start with the boost tubes. On 2011-2016 trucks the plastic cold-side tube cracks and the hot-side tube can come off the turbo outlet, and failures are reported under tow and at altitude. Listen for a whistle under load and look for codes like P0299, P1247 or P0402.
Does the 6.7L Powerstroke have a front-mount intercooler?
No. The charge-air cooler is an air-to-water core in the engine valley, cooled by the secondary coolant loop it shares with the fuel and transmission coolers. Intercooler upgrades for this engine replace that valley core or the pipes around it, not a radiator-style core up front.
How often should I change the air filter?
Ford calls for 45,000 miles or as required. If the truck works on dirt roads, job sites or fields, check it more often. A restricted filter or soot in the airbox can bring on MAF-related codes, so look there before you replace a sensor.
Is a cold air intake street legal on my F-350?
It depends on the part. The S&B 75-5104 carries CARB EO D-590-13 for the F-250 and F-350, and a CARB EO is the proof that a part is emissions-legal in all 50 states. That EO does not cover F-450 or F-550 trucks. Check the product page for an EO number that names your truck.
Will intake parts from a 2011-2014 truck fit my 2016?
Many will. The S&B intake and the cold-side boost pipe are catalogued 2011-2016 even though the turbo changed in 2015. The hot side is the exception: S&B splits its hot-side pipes between 2011-2015 and 2016 on. Many parts for 2017 and newer trucks are different.
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.