The BD Diesel Performance 1047035 is a heavy-duty, direct-fit replacement charge air cooler (CAC) intercooler hose and clamp kit engineered specifically for 2003–2007 Ford F-250, F-350, F-450, and F-550 Super Duty trucks and 2003–2005 Ford Excursions equipped with the 6.0L Powerstroke diesel engine. Engineered to meet three times their working pressure, these boots are constructed with 4 to 5 plies of genuine DuPont Nomex/aramid fibers embedded in high-grade silicone, featuring a specialized red iron oxide internal layer and fluorosilicone/fluorocarbon elastomeric barriers. This multi-layer architecture delivers extreme thermal resistance and complete impermeability to crankcase ventilation (CCV) oil blow-by mist and fuel vapors, preventing the softening, ballooning, and split seams that plague factory rubber boots.

Violent underhood boost blow-offs during heavy towing or wide-open throttle passes, split factory seams along clamp beads, sudden boost loss, sluggish throttle response, high exhaust gas temperatures (EGTs), heavy black exhaust smoke, and oil-slicked metal charge pipes causing boots to slide off under load are what this complete kit cures. Factory 6.0L rubber boots degrade rapidly under continuous thermal cycling and crankcase oil mist saturation, losing their structural integrity and blowing off past the pipe retention beads when subjected to aggressive performance tuning or heavy gross vehicle weights. The BD Diesel 1047035 kit overhauls the entire charge air path simultaneously with boots rated to hold over 100 PSI of boost pressure without expanding. It comes packaged as a complete system including four high-strength Nomex silicone boots and eight heavy-duty 300-series stainless steel spring-loaded constant-tension T-bolt clamps; metal CAC intercooler pipes and the intercooler core are sold separately.

It fits all 2003–2007 Ford Super Duty F-250, F-350, F-450, and F-550 trucks and 2003–2005 Ford Excursions equipped with the 6.0L Powerstroke turbo diesel engine (Note: will not fit E-Series van applications).

Fitment

• 2003–2007 Ford F-250 Super Duty 6.0L Powerstroke Turbo Diesel
• 2003–2007 Ford F-350 Super Duty 6.0L Powerstroke Turbo Diesel
• 2003–2007 Ford F-450 / F-550 Super Duty 6.0L Powerstroke Turbo Diesel
• 2003–2005 Ford Excursion 6.0L Powerstroke Turbo Diesel
• Constructed with 4 to 5 plies of genuine DuPont Nomex / aramid fiber for burst strength over 100 PSI
• High-temperature silicone outer layer with red iron oxide inner liner and fluorocarbon oil barrier
• Resists high thermal loads, extreme pressure spikes, and degradation from CCV oil saturation
• Includes eight heavy-duty 300-series stainless steel spring-loaded constant-tension T-bolt clamps
• Spring-loaded clamp bands maintain consistent clamping force through extreme engine heat cycles
• Engineered for direct drop-in fitment across factory hot-side and cold-side intercooler piping
• Backed by BD Diesel’s 12-Month, 24,000-Mile Parts Warranty

Park the truck on a level surface, engage the parking brake, and disconnect both negative battery cables. Allow the engine compartment and charge-air piping to cool completely before servicing. On the passenger side, loosen the factory T-bolt clamps on the hot-side charge pipe at the turbocharger compressor outlet and lower intercooler inlet using an 11mm (or 7/16-inch) deep socket, then remove the metal hot pipe and old boots. On the driver side, loosen the clamps at the upper intake elbow and lower intercooler outlet, then remove the cold-side tube and factory rubber couplers clear of the engine bay. Thoroughly clean the aluminum turbo compressor outlet, intake elbow neck, intercooler tank inlet/outlet stubs, and all metal charge pipe retaining ends using brake cleaner and a lint-free cloth to eliminate all pooled oil slick, road grime, and carbon residue (any residual oil film left on the retaining beads will cause boots to slip under boost). Slide the included BD spring-loaded stainless steel T-bolt clamps loosely onto each of the four Nomex 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 elbow, and both lower intercooler tank ports until fully seated. Reinstall the metal charge pipes into the opposite ends of the boots, making sure the pipes are centered and that each boot bridges the joint squarely without binding. Position every T-bolt clamp directly behind the raised metal retaining bead on each pipe neck (never clamp directly on top of the bead, which cuts 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 bringing manifold boost pressure to 24–28 PSI under load to verify a completely leak-free seal.