6.7 Powerstroke Cold Side Boot Split: Signs and the Permanent Fix
You are pulling a grade with a trailer behind you, you hear a whoosh under the hood, and the truck falls on its face. On a 6.7 Powerstroke, nine times out of ten the cold side boot just split.
The boot does not pop off the pipe. It splits or bursts, usually right at a fold where the rubber or plastic has been flexing for years. It is one of the most common parts we sell for these trucks, and it is a cheap fix once you know what you are looking at.
What the Cold Side Boot Is
Boost leaves the turbo hot, goes through the intercooler to cool down, then comes back to the engine through the cold side. The cold side boot is the flexible coupler that connects that pipe to the intake. Every pound of boost the turbo makes has to pass through it.
- 2011 to 2016 trucks use a plastic intercooler boot that cracks with age.
- 2017 and newer trucks use a rubber intercooler pipe that busts or rips under high boost and heat.
Heat cycles and oil mist from the CCV system make it brittle. Add a tune or heavy towing and boost pressure finishes it off.
Signs Your Cold Side Boot Split
- Sudden, big loss of power, usually under load or on the highway
- A loud whoosh or hiss from under the hood when you get on it
- Black smoke, since the engine is fueling for air it is not getting
- Check engine light or underboost codes, sometimes limp mode
- Oil film or soot around the coupler or on the radiator support
- Boost gauge that will not climb like it used to
How to Confirm It
- Look all the way around it. With the engine off and cool, check the intercooler pipe at the intercooler and at the intake. Splits often open on the bottom or the back side where you cannot see them from above, so use a light and a mirror.
- Squeeze it. A healthy boot is firm. A cracked, mushy or oil soaked boot is next.
- Boost leak test. If you still cannot see it, cap the intake at the turbo, pressurize the system with a boost leak tester and spray the joints with soapy water. Bubbles show the leak. Stay at or below the boost your truck normally makes.
Find a lot of oil inside the boot? That points to the factory CCV system. Read our 6.7 Powerstroke CCV guide.
The Fix, From Cheapest to Strongest
1. SPE Cold Side Replacement Hose, 2017 to 2026
The SPE Motorsport Cold Side Replacement Hose (S100158) is the most popular fix we sell for newer trucks.
- Direct fit for 2017 to 2026 6.7 Powerstroke
- 5 ply polyester reinforced silicone that handles more heat and pressure than the factory rubber
- No tuning required, works on stock and tuned trucks
- Simple, quick install
Best for: stock and mildly tuned trucks that just want the weak link gone.
2. SPE Cold Side Pipe, 2011 to 2026
The SPE Cold Side Intercooler Pipe (S100100) replaces the problem piece on both generations: the plastic boot on 2011 to 2016 and the rubber coupler on newer trucks.
- Billet anodized throttle body adapter and a 5 ply silicone coupler
- Built in reference ports for a boost gauge or injectables, no drilling
- No tuning required
Best for: 2011 to 2016 trucks, and anyone who wants boost reference ports.
3. Pusher HD 3 Inch Cold Side Charge Tube
Pusher replaces the factory charge tube with a mandrel bent, fully TIG welded 3 inch steel tube, a machined IAT sensor port and two 1/8 inch NPT auxiliary ports. Pick your years and throttle valve option:
- 2017 and newer: with throttle valve adapter (keeps the factory throttle valve) or with throttle valve replacement (off road use only)
- 2011 to 2016: with throttle valve adapter or with throttle valve replacement (off road use only)
Want both sides done? The Pusher hot and cold side set with throttle valve adapter replaces both tubes at once.
Best for: tuned trucks, heavy towing, and anyone who never wants to deal with it again.
4. Full Piping Kit
Planning a bigger turbo or more power? Do the whole boost path at once. See our intercooler piping kit comparison.
Which One Fits My Truck?
- 2011 to 2016: SPE cold side pipe or a Pusher cold side tube
- 2017 to 2026: SPE replacement hose, SPE cold side pipe or a Pusher cold side tube
Everything else for the boost side: 2011 to 2019 intakes and cooling and 2020 and newer.
FAQ
Why does my 6.7 Powerstroke keep splitting the cold side boot?
The factory coupler is rubber on 2017 and newer trucks and plastic on 2011 to 2016 trucks. Heat, oil mist and higher boost from tuning or towing break it down until it splits. A silicone hose or a metal charge tube fixes it for good.
Can you drive with a split cold side boot?
Only far enough to get off the road. The truck will make very little power, smoke and may go into limp mode. Replace it before you tow or drive any distance.
Do I need a tune after replacing the cold side boot?
No. The SPE replacement hose, the SPE cold side pipe and the Pusher cold side tubes with throttle valve adapter all run on the factory calibration.
What is the cheapest permanent fix for a 6.7 Powerstroke cold side boot?
For 2017 to 2026 trucks, the SPE Motorsport Cold Side Replacement Hose. It is 5 ply reinforced silicone and installs in place of the factory rubber coupler. For 2011 to 2016 trucks, the SPE cold side pipe.
Not sure what fits your truck? Send us your VIN or call 865 640 2097 and we will help you pick the right part.
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