The S&B Filters 76-1003B is a cast aluminum high-flow intake elbow and cold-side charge pipe kit that flows 49.6% more air than stock and includes dual NPT auxiliary ports.

The S&B Filters 76-1003B is a complete high-performance cast aluminum intake elbow and cold-side charge air cooler (CAC) intercooler piping upgrade 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-engineered and CNC-machined in-house by S&B, this kit replaces the restrictive factory cast iron elbow and throttle butterfly housing with a streamline-contoured cast aluminum elbow finished in a durable black powder coat. Designed to maximize velocity into the intake manifold plenum, this assembly delivers a verified 49.6% airflow increase over the factory system, significantly reducing turbulence and lowering exhaust gas temperatures (EGTs). Additionally, it features an integrated O-ring sealing flange that eliminates internal fastening bolt intrusions into the air stream and includes pre-tapped 1/8-inch NPT auxiliary ports for boost gauges, temperature probes, or water-methanol injection nozzles.

Severe airflow restrictions caused by factory throttle butterfly valves, brittle composite cold pipes prone to splitting under load, boost leaks around worn factory flange gaskets, elevated EGTs when towing, sluggish turbo spool, and the absence of clean auxiliary injection/monitoring ports are what this complete kit cures. On early 6.0L Powerstroke engines, the factory cast intake elbow incorporates internal throttle plate restrictions and abrupt angular transitions that create massive drag in the compressed air charge. The S&B 76-1003B kit completely clears the internal intake path, pairing the high-flow black elbow directly with a matching cold-side charge pipe, multi-ply silicone couplers, and heavy-duty clamps for an airtight, permanent boost connection. It is 50-state street legal under CARB Executive Order D-590-7 and includes the cast aluminum intake elbow, cold-side charge pipe, premium silicone boots, constant-tension T-bolt clamps, O-ring gasket, and threaded NPT plugs; hot-side intercooler piping is 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 (early round intake manifold flange configuration; for 2005–2007 trucks with redesigned intake manifolds, see S&B 76-1006B).

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
• High-flow cast aluminum construction outflows the stock intake elbow by 49.6%
• Eliminates factory throttle plate assembly for an unrestricted, streamline airflow transition
• Features an integrated O-ring groove for a leak-free mechanical seal without messy RTV
• Includes pre-tapped 1/8-inch NPT ports for straightforward boost gauge or water-meth injection setup
• Includes cold-side charge air pipe, 4-ply aramid-reinforced silicone boots, and T-bolt clamps
• Lowers exhaust gas temperatures (EGTs) and sharpens low-end turbocharger spool-up
• CARB exempt under EO # D-590-7 — 50-state emissions legal for street and highway use
• Backed by S&B Filters' Signature Lifetime Warranty

Park the truck on a level surface, engage the parking brake, and disconnect both negative battery cables. Allow the engine bay to cool completely before servicing. On the driver side of the engine, loosen the constant-tension clamps on the factory cold-side intercooler tube at the intercooler outlet and intake elbow using an 11mm (or 7/16-inch) deep socket, then remove the tube. Disconnect the wiring harness connector from the factory intake throttle valve actuator if equipped. Remove the factory mounting bolts securing the stock intake elbow to the intake manifold plenum and lift the old elbow clear of the engine bay. Thoroughly clean the aluminum intake manifold flange with brake cleaner and a lint-free cloth, ensuring no carbon, old gasket remnants, or grit fall into the open plenum. If not utilizing the pre-tapped 1/8-inch NPT ports on the S&B elbow for sensors or injection nozzles, apply high-temperature PTFE thread paste to the included brass/steel plugs and torque them securely into the elbow ports. Lightly lubricate the included S&B high-temperature O-ring with clean engine oil and seat it squarely into the machined groove on the base of the S&B cast aluminum elbow. Position the elbow onto the intake manifold flange, install the provided mounting hardware, and torque the bolts in an alternating cross-pattern to 10 ft-lbs (14 Nm). Slide the provided 4-ply silicone boots and constant-tension T-bolt clamps onto the cold-side charge pipe. Lightly spray the inner lips of the boots with isopropyl alcohol or aerosol hairspray to help them slide smoothly over the retaining beads. Seat the lower boot onto the intercooler outlet and the upper boot onto the S&B intake elbow, ensuring the pipe has at least 1/2-inch radial clearance around steering components and brake lines. Position each T-bolt clamp squarely behind the raised pipe retaining beads (never clamp directly on top of the bead). Using a calibrated torque wrench, tighten all four T-bolt clamp nuts 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 confirm zero charge-air whistling and complete boost retention.