The S&B Filters 83-2000 is a complete, direct-fit replacement hot and cold side charge air cooler (CAC) intercooler boot and clamp kit engineered specifically for 2003–2004 Ford F-250, F-350, F-450, and F-550 Super Duty trucks and 2003–2004 Ford Excursions equipped with the 6.0L Powerstroke diesel engine. Precision-manufactured in-house by S&B, this 4-piece silicone hose set includes the turbo discharge coupler, hot-side lower intercooler inlet boot, cold-side lower intercooler outlet boot, and cold-side upper intake elbow boot. Constructed with four plies of heat-stabilized aramid reinforcement embedded in heavy-duty silicone rubber, these boots are built to withstand high boost pressure spikes, continuous crankcase ventilation (CCV) oil blow-by mist, and extreme compressed charge air temperatures without softening, ballooning, or tearing along clamp contact points.

Loud underhood popping sounds under acceleration, sudden boost drop-off under heavy towing, elevated exhaust gas temperatures (EGTs), sluggish acceleration, excessive black exhaust smoke, and oil-soaked factory rubber boots blowing off metal retaining beads are what this complete kit permanently eliminates. Factory 2003–2004 6.0L charge air boots degrade rapidly under the combination of continuous heat cycling and engine blow-by oil mist, leaving the material slick, weak, and prone to blowing off under load. The S&B 83-2000 kit overhauls the entire charge air path simultaneously, restoring airtight boost delivery from the turbo compressor outlet straight into the engine intake manifold. It comes packaged as a complete system featuring four custom-molded silicone boots and eight heavy-duty, spring-loaded stainless steel constant-tension T-bolt clamps; metal CAC intercooler tubes and the intercooler core are sold separately.

It fits all 2003–2004 Ford Super Duty F-250, F-350, F-450, and F-550 trucks and 2003–2004 Ford Excursions equipped with the 6.0L Powerstroke turbo diesel engine running the early-style factory charge-air piping configuration (for late 2004.5–2007 trucks, see S&B 83-2001).

Fitment

• 2003–2004 Ford F-250 Super Duty 6.0L Powerstroke Turbo Diesel
• 2003–2004 Ford F-350 Super Duty 6.0L Powerstroke Turbo Diesel
• 2003–2004 Ford F-450 / F-550 Super Duty 6.0L Powerstroke Turbo Diesel
• 2003–2004 Ford Excursion 6.0L Powerstroke Turbo Diesel
• Complete 4-piece kit replaces every hot and cold side CAC boot in a single service
• Constructed with 4 plies of heavy-duty aramid reinforcement for extreme burst strength
• Premium high-grade silicone rubber resists high heat, pressure spikes, and CCV oil degradation
• Includes eight premium spring-loaded constant-tension stainless steel T-bolt clamps
• Engineered to exact OEM dimensions for direct drop-in fitment on 2003–2004 charge piping
• Eliminates high-boost boot blow-off, split seams, and lost turbocharger boost pressure
• Proudly manufactured in-house by S&B Filters and backed by a Lifetime Warranty

Park the truck on a level surface, engage the parking brake, and disconnect both negative battery cables. Allow the engine bay and charge-air system to cool completely before servicing. Starting on the passenger-side hot pipe, use an 11mm (or 7/16-inch) deep socket to loosen the factory T-bolt clamps on the upper turbo outlet hose and the lower intercooler inlet boot. Remove the metal hot-side pipe and unseat both factory rubber boots from the turbo compressor neck and intercooler tank inlet. Move to the driver-side cold pipe and loosen the clamps at the upper intake elbow and lower intercooler outlet, then pull the cold-side tube and factory boots clear of the engine compartment. Using brake cleaner and a clean lint-free cloth, thoroughly clean every aluminum and steel pipe connection neck, wiping away all pooled oil slick, road grime, and carbon scale (any residual oil film left on the retaining beads will cause boots to slip under boost). Slide the included S&B spring-loaded constant-tension T-bolt clamps loosely onto each of the four S&B silicone boots. Lightly spray the inside of each boot lip with isopropyl alcohol or aerosol hairspray to help them slide smoothly over the raised metal retaining beads without snagging. Slide the appropriate boots onto the turbo compressor outlet, intake manifold elbow, and both lower intercooler tank ports until fully seated. Reinstall the metal charge pipes into the opposite ends of the boots, verifying that the pipes are centered and that each boot bridges the joint without binding or kinking. Position every T-bolt clamp squarely behind the raised metal retaining bead on each pipe neck (never clamp directly on top of the bead, which damages the silicone). Using a calibrated torque wrench, tighten each T-bolt clamp nut to 9–12 ft-lbs (106–142 in-lbs) until the tension springs compress evenly. Reconnect both negative battery cables, start the engine, and perform a test drive under full boost to verify a leak-free seal.