Dorman 904-242 Intercooler Boot Kit

Durable Intercooler Boot Kit for Ford Excursion and Super Duty Models

The Dorman 904-242 intercooler boot kit is designed specifically for Ford Excursion, F-250 Super Duty, and F-350 Super Duty vehicles. Constructed from high-quality silicone rubber, this kit ensures reliable performance under extreme temperature and pressure conditions.

• Made from durable black silicone rubber for long-lasting use
• Maximum operating temperature up to 305°F and minimum down to -40°F
• Pressure rating up to 1400 psi for heavy-duty applications
• Specific fit for Ford Excursion, F-250 Super Duty, and F-350 Super Duty models
• Includes two boots connecting intercooler piping to the intercooler
• End 1 inside diameter of 3 inches and outer diameter of 3.25 inches
• Maximum length of 7.1 inches for proper fitment

Product Details and Specifications

The Dorman 904-242 intercooler boot kit is engineered to maintain optimal airflow between the intercooler piping and the intercooler itself. Its silicone rubber construction provides excellent resistance to heat, pressure, and environmental factors, making it suitable for demanding engine conditions. The kit includes two boots, each with a 3-inch inside diameter and 3.25-inch outer diameter, designed to fit precisely on Ford Excursion, F-250 Super Duty, and F-350 Super Duty models. With a maximum operating temperature of 305°F and a pressure rating of 1400 psi, this kit supports the performance needs of turbocharged diesel engines.

Common Applications and Problem Solving

• Replaces worn or cracked intercooler boots causing boost leaks
• Prevents loss of engine power due to air pressure drops
• Eliminates issues related to overheating or material degradation
• Restores proper connection between intercooler piping and intercooler
• Helps maintain engine efficiency and turbocharger performance

Installation Notes and Tips

Installation of the Dorman 904-242 intercooler boot kit requires basic mechanical skills and tools. Ensure the engine is cool before beginning work. Remove the old boots carefully to avoid damaging the intercooler or piping. Clean the connection points thoroughly to ensure a secure fit. Lubricate the inside diameter of the boots slightly to ease installation. Verify that clamps are tightened to manufacturer specifications to prevent leaks.

Quality Assurance and Warranty

Dorman parts are manufactured to meet or exceed OEM standards, providing reliable performance and durability. The 904-242 intercooler boot kit undergoes rigorous quality control to ensure fitment and material integrity. While specific warranty details may vary, Dorman typically offers a limited warranty covering defects in material and workmanship.