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Quick Fix! Replacing a Ripped Intercooler Pipe on a 6.7L Power Stroke

DW STAFF . October 15, 2024 . Diesel World

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A Common Repair Made Quickly and Easily

Today we’re going to address a very common problem: a ripped cold-side intercooler pipe on a 2019 6.7L Power Stroke. Our plan is to swap the ripped pipe with this fancy S&B cold-side intercooler pipe replacement (Part #83-1001). Not only will this fix our boost leak, but it will also look great when popping the hood any other time. Let’s get into it!

Step 1: Loosen the upper hose clamp of the Charge Air Cooler (CAC) outlet hose

Step 2: Loosen the lower hose clamp of the CAC outlet hose.

Step 3: Slide the hose off the upper hose barb and the intercooler outlet, and remove it from the vehicle.

Step 4: Depress the locking clip and remove the electrical connector from the air temperature sensor.

Step 5: Remove the temperature sensor harness retainer from the upper hose barb.

Step 6: Remove the spring clip from the throttle assembly being careful not to over stretch or bend it. Save the spring clip for later.

As you can see in these photos, the stock intercooler pipe is a little tired from the miles that are already on the truck (outside of the tear in the upper boot) and the S&B setup is extremely clean and looks great.

Step 7: Install the spring clip from Step 6 into the clip groove on the CAC hard pipe (A).

Step 8: Stretch the O-ring (B) by hand while adding a thin coat of clean diesel engine oil to the O-ring. Work your way around the entire O-ring, gently stretching and oiling as you go. After stretching, verify that the outside diameter of the O-ring touches all around the inside of the O-ring groove of the CAC hard pipe (A) as shown below. If the outside diameter of the O-ring feels loose in the O-ring groove, gently stretch the O-ring by hand again.

Step 9: Once you have everything positioned properly, tighten and torque the T-bolt hose clamp to 75 lb-in.

And we’re back on the road with no boost leaks! We told you guys this would be a quick one! Thanks to S&B for having a great product with awesome and very in-depth instructions to help us get this F-350 back on the road.

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