Dorman 904-220 Intercooler Boot Kit

Dorman 904-220 Intercooler Boot Kit

Dorman 904-220 is a specific-fit intercooler boot kit for diesel charge air system repairs on select Ford trucks and vans. It is built with rubber and metal components to match the original sealing setup and restore a secure connection between the intercooler, charge air cooler tube, and related adapters.

For Ford E-350 Econoline, E-350 Club Wagon, Excursion, F-250 Super Duty, and F-350 Super Duty applications, this kit addresses worn or damaged intercooler boots with OE-style fitment and materials selected for durability under boost and heat.

• Specific-fit intercooler boot kit for select Ford diesel applications
• Rubber and metal construction for sealing and retention
• Black and natural finish
• 3-inch inside diameter with 3.25-inch outer diameter
• Rated for up to 150 PSI operating pressure
• Designed for temperatures from -40°F to 180°F
• Compatible with charge air cooler tube and cylinder head inlet connections on listed vehicles

Detailed Product Overview

This intercooler boot kit is engineered to match the original seals used on specified vehicles, helping restore the integrity of the intercooler connection points. Dorman 904-220 is a direct-replacement style solution for charge air system service where the boot has cracked, loosened, or no longer seals properly. The kit’s rubber-and-metal design supports a secure fit in high-pressure turbocharged diesel environments, making it a practical choice for Ford E-350 Econoline, E-350 Club Wagon, Excursion, F-250 Super Duty, and F-350 Super Duty models.

This part cross-references 1C3Z6C640LA and 1821764C1 for the same application.

Common Repair Uses

• Boost leaks caused by a deteriorated intercooler boot
• Loss of charge air pressure at the intercooler connection
• Cracked, hardened, or oil-soaked boot material
• Air seepage at the engine-to-charge-air-cooler tube connection
• Sealing issues at the cylinder head inlet to charge air cooler adapter

Installation Notes and Tips

Verify the vehicle’s charge air cooler tube or cylinder head inlet configuration before installation. Clean the mating surfaces thoroughly and inspect adjacent clamps, tubes, and adapters for wear or deformation that could affect sealing. Confirm the boot dimensions and application notes against the vehicle’s original setup before service.

• Fits 2003 Ford E-350 Club Wagon, engine to charge air cooler tube; blue hose
• Fits 2003 Ford E-350 Club Wagon, cylinder head inlet to charge air cooler adapter; red oxide
• Fits 2000-2003 Ford Excursion, cylinder head inlet to charge air cooler adapter; red oxide
• Fits 2000-2003 Ford Excursion, engine to charge air cooler tube; blue hose
• Fits 1999-2003 Ford F-250 Super Duty, cylinder head inlet to charge air cooler adapter; red oxide
• Fits 1999-2003 Ford F-250 Super Duty, engine to charge air cooler tube; blue hose
• Fits 1999-2003 Ford F-350 Super Duty, cylinder head inlet to charge air cooler adapter; red oxide
• Fits 1999-2003 Ford F-350 Super Duty, engine to charge air cooler tube; blue hose
• Fits 1998-2002 Ford E-350 Econoline Club Wagon, cylinder head inlet to charge air cooler adapter; red oxide
• Fits 1998-2002 Ford E-350 Econoline Club Wagon, engine to charge air cooler tube; blue hose
• Fits 1998 Ford E-350 Econoline, cylinder head inlet to charge air cooler adapter; red oxide
• Fits 1998 Ford E-350 Econoline, engine to charge air cooler tube; blue hose

Quality Assurance

Dorman designs replacement components to match original sealing requirements for specified vehicle applications. Part number 904-220 is built for reliable performance and durability in the listed Ford diesel fitments.