How to Replace Intercooler Boots on a Second Gen Cummins

When you put a 67-9 on a second gen and start pushing 50 pounds of boost, the factory intercooler boots become the weak link fast. Willard proved that on the last test drive when the boot slid clean off the intercooler mid-drive.

Today we are doing the full install of our Power Driven Diesel intercooler boot kit and breaking down exactly why it holds where factory rubber gives up.
Willard is Todd's second gen tow truck, and this thing needs to be reliable under load. Towing at 38 pounds of boost generates serious heat in those boots, and tight clamps will only hold a factory boot for so long. When it lets go while you are hauling a trailer, you go from a diesel performance truck to crawling toward the shoulder on 200 horsepower with nowhere safe to pull off. That is the real-world case for upgrading before you need to.

The Power Driven boot kit uses a five-layer aramid fiber construction against the factory four-layer thin rubber. Aftermarket options that look similar are usually a polyester blend, and that material gets brittle with heat cycles. The added thickness on these boots does two things: it gives you stronger material, and it physically grips the intercooler tubes better so the boot cannot slide out from under the clamp the way the factory piece did. These same boots have been run at 120 to 150 pounds of boost and have handled years of hard towing grades without giving up.

The second gen kit includes two boots sized differently for driver and passenger side, along with heavy duty constant tension clamps. The spring in those clamps keeps pressure on the boot as it heats up and moves, which is exactly what factory clamps cannot do. The included clamps are half inch hardware where the factory was 7/16, so grab the right socket before you start tightening.

A few install details from the video worth paying attention to: pull the air filter assembly out first to give yourself room to work, wipe the tube connections clean before sliding the boots on, and leave a little boot material exposed below the clamp so it has something to grip into. If you are running serious boost, take a minute to bend that fender lip back slightly on the driver's side so it cannot cut into the boot material over time. Once everything is clocked and tightened to coil bind, go back and check all the clamps after the first couple heat cycles. After that you are good for a long time.

Subscribe and hit the bell so you catch every build update on Willard and the rest of the shop trucks.
Shop everything mentioned in this video at PowerDriven.com — links below.

Shop Power Driven Diesel: https://www.powerdriven.com

Power Driven Diesel Intercooler Boot Kit (2nd Gen):

https://powerdriven.com/products/power-driven-high-performance-engine-boot-kit-94-02-2nd-gen-dodge-cummins?_pos=1&_sid=46ae7d3fd&_ss=r
0:00 Intro and why the boot blew off
0:33 Why factory boots fail at high boost
1:12 Removing the air filter assembly
1:46 Loosening and removing the factory clamps
2:07 Pulling the passenger side tube assembly
2:38 Removing the driver's side boot
3:15 Factory boot vs Power Driven boot comparison
3:36 Five layer aramid fiber construction breakdown
4:08 What comes in the second gen boot kit
4:35 Heavy duty constant tension clamps explained
5:01 Swapping boots onto the passenger side tube
6:02 Cleaning the tubes and sliding new boots on
7:44 Swapping boots onto the driver's side tube
8:38 Reinstalling the passenger side tube assembly
9:05 Getting the intercooler boot seated and snugged
10:47 Fender lip tip for high boost builds
11:03 Installing the driver's side tube
12:34 Clamp tightening technique and coil bind explained
13:29 Reinstalling the air filter assembly
14:15 Post install tips and wrap up
Power Driven Diesel is a specialty performance shop engaged in the engineering and development of high-performance turbo diesel technologies.

Contact Us:
435-962-9555
info@powerdrivendiesel.com

https://powerdriven.com
https://www.facebook.com/powerdrivendiesel/
https://www.instagram.com/powerdrivendiesel

Видео How to Replace Intercooler Boots on a Second Gen Cummins канала Power Driven