The late 2003-2007 Ford F-series super-duty trucks came equipped with a 6.0L Powerstroke diesel engine making them a powerhouse and great work trucks. However, they have some shortcomings that gave these engines a bad reputation. We brought in two different models of these trucks to dissect and investigate the issues. What we came up with is our upgraded 6061 aluminum HPS Cold Side and Hot Side Charge Pipe Kit that addresses the weak links in the charge air system.

The difference between HPS Complete Charge Pipes Kit and other aftermarket kits are listed below.

HPS Hot Side Charge Pipe with Mounting Brace
The factory Hot Side is commonly known to fail at the turbo boots. We found that the factory steel Hot Side pipe is a major culprit in causing boost leaks and power loss problems on all years of the 6.0L Powerstroke Diesel engine. The factory Hot Side pipe sits in the engine compartment freely with nothing holding it in place except for the boots, placing a lot of stress on the boots. Our approach to this issue is to create the pipe out of 6061 aluminum tubing to reduce the weight on the boots by about 50%. On top of that, we designed a brace to securely mount the Hot Side pipe, further relieving any weight and stress from the boots.

HPS Cold Side Charge Pipe
When the 6.0L Powerstroke Ford F-Series first came out, it was equipped with plated steel pipes for both hot and cold side. The pipes were heavy as well as robust. During the mid-cycle refresh for the 2005 models, the cold side pipe was replaced to an injection molded plastic charge pipe. Owners of these trucks would begin noticing loss of power caused by cracks in the plastic pipe. The HPS Cold Side Charge Pipe, modeled off of the OEM part, replaces the OEM hard and brittle plastic charge pipe with our mandrel bent 6061 aluminum piece. Our aluminum Cold Side Charge Pipe is also an upgrade to early model steel pipes for those who want to reduce weight and simply want to add some color to the engine compartment.

HPS Ultra High Temp 4-ply Aramid Reinforced Fluoro-lined Silicone Boots
In our analysis, the stock intercooler boots are made of silicone and is reinforced with 2 layers of polyester. Because the 6.0L Powerstroke engines breathe a lot of oil through the turbo, silicone hoses will degrade causing them to become soft and gummy. Over time, the boots will either rip or blow through. On our HPS direct fit intercooler boots for the 6.0L Powerstroke Diesel Ford F-Series trucks, we added a fluoroelastomer liner to allow constant flow of oil without the negative consequences. We also replaced the 2 layers of polyester with 4 layers of Aramid fiber, raising the maximum operating temperature to 500F. The added layers also plays a role in allowing higher operating pressures, keeping your truck on the road longer.

HPS Heavy Duty Spring-Loaded T-Bolt Clamps
We provide Stainless Steel Spring-Loaded T-Bolt clamps with our intercooler boot kits on every connecting point of the charge air system for the 6.0L Powerstroke Diesel Ford F-Series trucks. The housing and band are made of a 300 series stainless steel and offer great corrosion resistance. The Bolt, Nut, and Spring are zinc plated steel for excellent reusability and protection from the elements.

REMARK: The complete kit for the 6.0L Powerstroke Diesel Ford F-Series trucks is designed and modeled based on OEM parts. This kit will work with direct bolt-on intake kits as well as direct fit upgraded intercoolers.

HPS Intercooler Pipe Kit Features and Specification

- Unique mounting brace design on the hot side for added structural rigidity to the Hot Side pipe.
- Mandrel bent 6061 aluminum tubing increase air volume and air flow. Upgrade 05-07 model factory plastic charge pipe.
- Includes HPS 4-ply aramid reinforced fluoro-lined silicone couplers for excellent oil resistance minimizing premature failure (Maximum temperature rating: 500F)
- Spring-Loaded T-Bolt Clamps. Industrial grade constant tension clamps eliminate the need for maintenance in fluctuating temperature conditions.
- Includes easy to follow step-by-step installation manual with clear pictures and instructions to guide the installer throughout the whole process.
- No modification is required during the installation.
- NOT CARB Complaint
- System Type: Charge Pipe (Hot & Cold Side) with Silicone Hoses

Vehicle Application
2007 Ford F350 F350 F450 F550 Superduty Pickup 6.0L V8 Diesel Turbo
2006 Ford F350 F350 F450 F550 Superduty Pickup 6.0L V8 Diesel Turbo
2005 Ford F350 F350 F450 F550 Superduty Pickup 6.0L V8 Diesel Turbo
2004 Ford F350 F350 F450 F550 Superduty Pickup 6.0L V8 Diesel Turbo
2003 Ford F350 F350 F450 F550 Superduty Pickup 6.0L V8 Diesel Turbo

Compatible with OEM part numbers
3C34-6C640-CA
3C34-6C640-DA
3C34-6K769-AB
3C3Z-6K769-CA
5C34-6C646-AH
5C34-6K769-AA
6C34-6C640-AA
6C34-6C640-BA
6C34-6C640-CA
6C34-6C646-AF
6C3Z-6C640-A
6C3Z-6C640-AA
6C3Z-6C640-B
6C3Z-6C640-C
6C3Z-6C646-A
6C3Z-6C646-BA
6C3Z-6K769-B