I had the intercooler boot on the passenger side next to the radiator pop off yesterday. An inspection of the boot the clamp and the tube indicate no damage it looks like it just popped off.

Could this just be a case of the rubber connector is worn? (133,000 miles) or or could this be a sign of something more serious? I was towing on the highway but I wasn't under high boost or a heavy load on.

Thanks in advance

 

My hot side boot popped off as well the other week, but it was at the turbo. It scared the hell out of me. I wasn't towing or running hard, just cruising down the road.
I put it back on and it popped off again.
Then I totally removed the boot and washed it really good (degreaser) and dried it off and re-installed it. No problems since.
My theory is that a fine layer of oil coated the interior of the boot/turbo and the clamp had loosened up a little and the clamp wasn't in the right spot.
When I re-installed everything I made sure to put the clamp in the right spot and tighten the hell out of it.
So far no more problems.

 

I have popped some boots here and there. Can certainly scare you if you have never experienced it before. Nice smoke production afterwards, too!

If you don't see anything obviously wrong with the boot, then it is likely the oily mist that your CCV introduces into your intercooler pipes penetrated your stock (?) silicone, inferior boots and caused it to loose its grip on the intercooler connection. You can thoroughly clean the surface of the intercooler connection with some degreaser, then use brake cleaner to remove the degreaser (unless you have plastic intercooler connectors), and then re-attach the boot. It is impossible to get the oil out of the silicone boot, so you will be destined to repeat this episode unless you replace the stock boots (you have stock boots?) with the new material everyone is using now. The new material does not become saturated with oil like the old stock boots do, and they will not pop off unless the clamp is loose.

 

I have stock boots. What is this new material that everyone is using now and where can I get some???????

 

These are the boots:

CAC 6.0L Intercooler Boot Kit for Ford 03-07

This is one place to get them. There are others as well. Shop around for price.

This is the NEW material (from RiffRaff site):
"Our boots consist of 4-ply Aramid reinforced silicone hoses that are specially made for Riffraff Diesel to withstand extreme temperatures to approximately 550 degrees F (vs. standard couplers that are good to 350 degrees F) and tested up to 180 psi working pressure.

100% Made In The USA! Available in Blue, Pink, Red and Black."

Pretty much everyone is now using that 4 ply aramid material mentioned above.

 

All of my boots were popping off even after cleaning and the hairspray trick...I got fed up and bought the red RiffRaff kit with clamps and couldn't be happier!

 

Red tops with red boots... Looks great!

 

Thanks to all for all the advice, I ordered the riffraff parts for all the boots plus the plastic cold side tube today. Any installation tips or things I should know before installing on Wednesday?

 

I spoke with a guy from RiffRaff directly last week when I did my boots and he recommended cleaning the intercooler fittings, turbo and intake fittings with brake cleaner then putting boots on and tightening them TIGHT. Their clamps are not constant tension clamps like the OEM Ford ones with the spring between the nut and clamp so you can really tighten them on the turbo, pipes and intake but don't overtighten the ones on the intercooler inlet and outlet if you still have the stock plastic intercooler.

 

Riff Raff also sells intake plenum inserts that strengthen the intake and let you crank down on the clamps as hard as you want - at least, they do for the 7.3L. I have them on mine and I highly recommend them! I don't know much about no 6.0 though .

 

Never saw those, good to know...

 

RDP Plenum Reinforcing Inserts - Ford 7.3L 99.5-03

Stewart

 

good stuff. Installed over the weekend. get tbolt clamps too my hose clamps were bent and coming apart from being over tightened.

edit oops just realized OP is a 6.0 no clue about them....

.

 

Oops x2.

Stewart

 

I've been running a combination of Dieselsite and Riffraff boots for the last 8 years or so and have only had one pop off (earlier this year). I checked the tension on all my other boots during the repair (60 in-lbs) and several were loose. I seem to be taking the CAC tubes off at least once or twice a year so never really thought about checking their tension. After my scare on the freeway this past spring I check them every 1-2 oil changes.