1994-2002 Ford 7.3L Powerstroke Air Intake Accessories

Intake accessories on the 1994-2002 Ford 7.3L Powerstroke

The joints between the airbox, the turbo, the intercooler and the plenums are sealed with rubber boots, and Ford held them with spring clamps. Because the crankcase ventilation vents into the intake, those boots sit in a film of oil mist for their whole life. On late-1999 to 2003 trucks, the 5-bolt GTP38 compressor housing decides which cold-side boot fits, which is why boot kits are cut by year. The sensors live here too. The PCM reads boost through the MAP sensor, and this collection also carries ambient, air charge and intake air temperature sensors for the years they fit.

What fails and why

Oil mist from the crankcase ventilation breaks the boots down over time until one lets go, and the factory spring clamps distort and loosen beside them. You feel it as low boost and sluggish response, you see it as oily residue at a joint or black smoke, and it gets worse when you tow. Age drives it, and tuned trucks get there sooner. Many owners also report the flexible boot between the passenger plenum and the Y-pipe weeping oil and boost. A dirty air filter speeds the whole process up, because it raises crankcase vacuum and pulls more oil into the intake. Before you condemn the turbo for low boost, pressure-test the charge system and find the leak.

Stock replacement vs. upgrade

If you only want factory fit, the Mishimoto factory-fit boot kit for 1999.5-2003 trucks replaces the stock boots. If the truck tows or runs a tune, step up to the S&B 83-2011 hot and cold side kit with 4-ply aramid-reinforced boots, and swap the factory spring clamps for the BD Diesel 1047020 constant-tension clamp kit. BD also sells a high-torque hose clamp on its own for a single joint. For dusty work, a pre-filter wrap over the element protects the filter, and the S&B Precision II kit cleans and re-oils a cotton element.

What we carry

• S&B: the 83-2011 hot and cold side boot kit, a 4 in silicone coupler with clamps, WF-series filter wraps and the Precision II cleaning and oil kit.
• BD Diesel: the 1047020 constant-tension clamp kit, a high-torque hose clamp and the 1030750 Brakeloc heat riser control.
• Mishimoto: the factory-fit boot kit for 1999.5-2003.
• Banks Power: the 42650 pre-filter wrap for its Ram-Air filters.
• Alliant Power: MAP and ambient air temperature sensors plus a 2-wire pigtail.
• XDP: MAP, air charge temperature and intake air temperature sensors.

Complete cold air intakes are in our diesel intakes collection, and the rest of the engine is under Powerstroke parts.

Fitment notes

Most sensors split by body style. For MAP sensors, the Alliant AP63489 and XDP XD1011 are listed for 1994-1997, and the Alliant AP63492 and XDP XD1045 for 1999-2003. The Alliant AP63490 ambient air temperature sensor is a 1994-1997 part, the XDP XD1040 air charge temperature sensor is listed for 1999-2003, and the XDP XD1039 intake air temperature sensor covers 1995-2003. Filter wraps follow the filter: WF-1019 and WF-1031 are listed for 1994-1997, WF-1020 and WF-1040 for 1998-2003. The Banks 42650 is made for Banks Ram-Air filters 42158 and 42188, so it only makes sense if you run one. Super Duty boot kits are listed 1999.5-2003, and an early-1999 truck built before December 1998 has its own intake setup. When in doubt, verify by VIN.

Frequently asked questions

Should I replace the clamps when I replace the boots?

On most 7.3L trucks it is worth doing. The factory spring clamps distort and loosen with age, and a loose clamp undoes a new boot. The BD Diesel 1047020 kit replaces the factory spring clamps with constant-tension clamps.

Which MAP sensor fits my truck?

It depends on the body style. For 1994-1997 OBS trucks, the Alliant Power AP63489 and the XDP XD1011 are the listed parts. For 1999-2003 Super Duty trucks, look at the Alliant Power AP63492 or the XDP XD1045.

Do I need a pre-filter wrap?

If the truck works in dust, it is good protection for the filter. Ford calls for replacing the air filter at 15,000 miles or 12 months in dusty use, half the normal interval, and a wrap catches coarse dirt before it reaches the element. Match the wrap number to your filter.

Why do my boots keep getting oily?

The 7.3L vents its crankcase into the intake, so the boots see oil mist all the time. A dirty filter pulls even more oil through by raising crankcase vacuum. Keep the filter fresh, and use reinforced boots when you replace soaked ones.

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.