The Ford Motorcraft 6C3Z-6C640-B is a genuine OEM hot-side lower charge air cooler (CAC) intercooler-to-pipe boot engineered specifically for 2003–2007 Ford F-250, F-350, F-450, and F-550 Super Duty trucks, 2003–2005 Ford Excursions, and 2004–2010 Ford E-Series vans equipped with the 6.0L Powerstroke diesel engine. Positioned down low on the passenger side of the radiator support, this heavy-duty molded silicone boot connects the lower end of the hot-side metal CAC pipe directly to the inlet neck of the intercooler. Engineered directly to Ford factory specifications with heavy-duty internal reinforcement fabric and an oil-resistant inner lining, it is built to withstand high boost pressures, extreme compressed charge-air temperatures, and constant chassis vibration without tearing, swelling, or blowing off.

Loud underhood popping noises under acceleration, sudden and complete loss of boost pressure, sluggish acceleration, high exhaust gas temperatures (EGTs), heavy black exhaust smoke, and oily soot accumulation across the lower passenger-side radiator support are what this boot cures. The lower hot-side connection operates in an extremely harsh environment: it receives the high thermal load of uncooled compressed air while also accumulating crankcase ventilation (CCV) oil mist that pools in the lowest point of the charge air system. Over time, oil saturation softens and degrades standard aftermarket rubber hoses, causing them to balloon, slip past the retention beads, or split along clamp edges. The genuine Ford 6C3Z-6C640-B delivers exact factory diameter and bead-lock retention to guarantee a permanent, high-boost seal under the heaviest towing loads. It is a genuine Ford OEM molded silicone lower hot-side CAC boot; spring-loaded T-bolt clamps (Ford 1C3Z-6K786-BA) and metal CAC tubes are sold separately.

It fits all 2003–2007 Ford Super Duty F-250, F-350, F-450, and F-550 trucks, 2003–2005 Ford Excursions, and 2004–2010 Ford E-250, E-350, and E-450 Econoline vans equipped with the 6.0L Powerstroke turbo diesel engine (lower hot-side intercooler inlet position).

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
• 2004–2010 Ford E-250 / E-350 / E-450 Econoline Van 6.0L Powerstroke Turbo Diesel
• Genuine Ford OEM replacement ensures exact factory fitment, diameter, and bead engagement
• Heavy-duty multi-layer reinforced silicone withstands extreme thermal cycling and high boost levels
• Oil-resistant internal barrier layer protects against CCV blow-by oil mist pooling and degradation
• Eliminates lower intercooler boot blow-off, split seams, and lost turbocharger boost pressure
• Precision-molded retention grooves match factory CAC pipe and intercooler inlet beads
• Direct replacement for original factory part number 6C3Z-6C640-B
• Backed by Ford Motorcraft’s 2-Year, Unlimited-Mileage Warranty

Park the truck on a level surface, set the emergency brake, and disconnect both negative battery cables. Allow the engine compartment to cool completely before servicing charge-air cooler connections. To access the lower passenger-side intercooler connection cleanly, work from beneath the front bumper or remove the passenger-side front inner fender liner. Loosen the spring-loaded constant-tension T-bolt clamps on both ends of the lower hot-side boot using an 11mm (or 7/16-inch) deep socket. Work the boot off the aluminum intercooler inlet neck and the lower end of the hot-side metal CAC tube, then remove the boot and clamps from the truck. Thoroughly clean the cast aluminum intercooler inlet neck and the metal tube retaining bead using brake cleaner and a clean, lint-free rag to eliminate all pooled engine oil, grit, and road grime (any oil residue left on the metal beads will cause boots to slide off under high boost). Inspect the metal tube and intercooler inlet neck for cracks, burrs, or deformation. Slide the constant-tension T-bolt clamps onto the new Ford 6C3Z-6C640-B boot. Lightly spray the inside of the boot with isopropyl alcohol or aerosol hairspray to help it slide smoothly over the raised metal retaining beads without snagging. Push the boot onto the intercooler inlet neck until firmly seated against the positive stop, then align and seat the lower end of the hot-side metal pipe inside the opposite end of the boot. Position the T-bolt clamps directly behind the raised metal retaining beads (do not clamp directly over the beads, as this can pinch and cut the silicone). Tighten both T-bolt clamps until the tension springs compress to factory specification (typically 9 to 12 ft-lbs / 106 to 142 in-lbs). Reinstall the inner fender liner if removed, reconnect both negative battery cables, and perform a test drive under load to confirm complete boost pressure retention.