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The factory cold side intercooler pipe on the 6.7 Powerstroke is plastic, and it’s a known weak point — heat cycling, boost pressure and vibration eventually crack or split it, especially on trucks that tow or run a tune. The aftermarket response is almost universally the same fix: replace the plastic section with mandrel-bent aluminum or steel tubing and a reinforced silicone boot rated well above stock boost pressure. The main differences between brands are tube diameter (3″ to 3.5″), boot ply count, and whether the kit is a direct OEM-shaped replacement or a slightly re-routed “upgrade” pipe. Note that 2011-2016 and 2017+ trucks use different pipe shapes, so match the kit to your model year, not just the engine.
| # | Product | Price | Where to buy |
|---|---|---|---|
| 1 | Motorcraft OEM Cold Side Intercooler Pipe | $150-$220 | Amazon · eBay |
| 2 | S&B Cold Side Intercooler Pipe | $280-$310 | Amazon · eBay |
| 3 | Sinister Diesel Cold Side Charge Pipe | $300-$410 | Amazon · eBay |
| 4 | XDP Direct-Fit Intercooler Pipe Upgrade | $230-$260 | Amazon · eBay |
| 5 | SPELAB Cold Side Intercooler Pipe Kit | $140-$180 | Amazon · eBay |
| 6 | SPE (Snyder Performance Engineering) Cold Side Pipe | $300-$350 | Amazon |
| 7 | H&S Motorsports Intercooler Pipe Upgrade Kit | $270-$300 | Amazon · eBay |
| 8 | Wehrli Custom Fabrication Cold Side Intercooler Pipe Kit | $400-$420 | Amazon · eBay |
| 9 | Pusher Intercoolers Cold Side Pipe | $399+ | Amazon · eBay |
The picks, in detail
Motorcraft OEM Cold Side Intercooler Pipe
The factory replacement part — same plastic construction and shape as what’s failing, but a fresh part at OEM fitment with Ford’s warranty backing. The right call if you want a guaranteed-fit repair rather than an upgrade, and don’t tow heavy or run a tune.
- Direct OEM-fit replacement (BC3Z-6F073-D for 2011-2016)
- Factory plastic construction
- Black finish matching factory appearance
- 1-year warranty
- Guaranteed direct fit, zero routing questions
- Cheapest option that doesn’t require any fabrication knowledge
- Keeps warranty-friendly factory appearance
- Same plastic construction that failed in the first place — a like-for-like repair, not an upgrade
- Will eventually face the same heat/boost fatigue issue
- No performance benefit over stock
S&B Cold Side Intercooler Pipe
The most commonly recommended upgrade pipe in this category — a 3.5″ polished aluminum tube with a 5-ply silicone boot, sized up from the factory diameter for genuinely improved airflow rather than just swapping material.
- 3.5″ polished aluminum tube
- 5-ply high-temp silicone boot
- Larger than stock diameter for reduced restriction
- Year-specific kits for 2011-2016 and 2017-2024
- Larger diameter gives a real airflow improvement, not just durability
- 5-ply boot rated well above stock boost levels
- Widely reviewed and the most-recommended option in this category
- One of the pricier aftermarket options
- Polished finish requires occasional cleaning to stay looking new
- Overkill if you just want a durable stock-diameter replacement
Sinister Diesel Cold Side Charge Pipe
A 6061 aluminum alloy pipe with mandrel-bent smooth bends and a 4-ply silicone boot rated to 400 psi, positioned as a durability-focused alternative to S&B’s airflow-focused pitch.
- 6061 aluminum alloy construction
- Mandrel-bent smooth bends
- 4-ply silicone boot rated to 400 psi
- Direct-fit for 2011-2016 or 2017-2026 kits
- 400 psi boot rating comfortably exceeds anything a street tune will produce
- Smooth mandrel bends reduce flow restriction at bends
- Competitively priced against S&B
- 4-ply boot vs S&B’s 5-ply, a real if modest spec difference
- Less brand recognition among diesel-specific shops than S&B
- Still needs correct year-specific kit selection
XDP Direct-Fit Intercooler Pipe Upgrade
A mandrel-bent, bead-rolled 3″ steel pipe rather than aluminum — steel trades a little weight for extra durability against physical damage, and XDP’s kit is priced as the value alternative to S&B and Sinister.
- 3″ mandrel-bent, bead-rolled steel construction
- Bead-rolled ends for secure boot clamping
- Direct-fit OEM-style routing
- 2011-2016 specific kit
- Steel construction is more resistant to physical dents/damage than aluminum
- Bead-rolled ends give a more secure clamp than plain tube ends
- Lower price than S&B or Sinister
- Steel is heavier than the aluminum alternatives
- Smaller 3″ diameter than S&B’s 3.5″ upgrade
- Steel can rust over years if the coating chips
SPELAB Cold Side Intercooler Pipe Kit
A budget aluminum kit with a high-temp silicone coupler, positioned well below the established diesel-specific brands on price while covering the same 2011-2016 and 2017-2024 fitments.
- Aluminum alloy tubing
- High-temp silicone couplers
- Direct bolt-on fit
- Separate kits for 2011-2016 and 2017-2024
- Lowest price among the aluminum upgrade options
- Covers the same year-specific fitments as the premium brands
- Reasonable choice for a budget-conscious daily driver, not a tow rig
- Less established reputation and long-term reliability data than S&B or Sinister
- Boot ply count and pressure rating aren’t as clearly documented
- Support/warranty channel is less established for US buyers
SPE (Snyder Performance Engineering) Cold Side Pipe
Includes a billet anodized throttle-body adapter as part of the kit, which the other options on this list don’t — a detail aimed at trucks already running other SPE intake components rather than a standalone budget pick.
- Aluminum cold side pipe
- Billet anodized throttle body adapter included
- 5-ply silicone coupler boot
- Designed to pair with SPE’s broader intake lineup
- Throttle body adapter is a genuine added-value component, not just a pipe
- 5-ply boot matches the top-tier S&B spec
- Good fit if you’re already running other SPE parts
- Pricier if you don’t need the throttle body adapter
- Less mainstream than S&B for a standalone pipe purchase
- Narrower appeal outside the SPE ecosystem
H&S Motorsports Intercooler Pipe Upgrade Kit
Positioned as a direct, no-tuning-required upgrade for 2011-2016 trucks, roughly $10 less than the equivalent S&B kit while targeting the same durability and airflow improvements.
- Aluminum upgrade pipe
- No tuning changes required
- Reinforced silicone boot
- 2011-2016 and 2017-2025 kit options
- No-tuning-required positioning removes a common buyer worry
- Priced slightly below the equivalent S&B kit
- Comes from an established diesel-performance parts maker
- Slightly less brand recognition specifically for this part than S&B
- Boot ply spec less prominently documented than competitors
- Still requires correct year-specific selection
Wehrli Custom Fabrication Cold Side Intercooler Pipe Kit
A 3.5″ kit from a diesel-fabrication specialist better known for high-output builds — the pick for a truck running higher boost than a mild street tune, where a fabrication-grade pipe is worth the premium.
- 3.5″ aluminum construction
- High-output-oriented design
- Reinforced silicone couplers
- 2017-2024 fitment
- Built by a shop known for high-boost diesel fabrication, not a generic parts importer
- 3.5″ diameter matches the largest options on this list
- Suited to trucks pushing well beyond stock boost
- One of the priciest options on this list
- More capability than a mild street truck needs
- 2017+ only — no 2011-2016 kit found in this search
Pusher Intercoolers Cold Side Pipe
The premium end of this list, from a company that also builds upgraded intercoolers for the 6.7 Powerstroke — a pipe sized to match a Pusher intercooler upgrade rather than the stock unit.
- Aluminum construction sized for high-flow applications
- Designed to pair with Pusher intercooler upgrades
- Reinforced boot
- 2017+ fitment
- Matched sizing if you’re also upgrading to a Pusher intercooler
- Built for genuinely high-flow, high-boost applications
- Established reputation in the diesel performance space
- Highest starting price on this list
- Most value if paired with their intercooler, less so as a standalone swap
- Overkill for a stock-power daily driver
Buying tips
- Confirm your truck’s model year before ordering — 2011-2016 and 2017+ 6.7 Powerstrokes use differently shaped cold side pipes, and most kits are sold as year-specific.
- If you just want reliability and don’t tow heavy or run a tune, the Motorcraft OEM replacement or a budget aluminum kit (SPELAB) is genuinely sufficient — you don’t need the largest-diameter kit to fix a cracked factory pipe.
- Boot ply count (4-ply vs 5-ply) and pressure rating matter more than the tube material alone — check the boot spec, not just whether the pipe is aluminum or steel.
- A larger 3.5″ pipe (S&B, Wehrli) only pays off if you’re also running more boost than stock — on an unmodified truck, a 3″ replacement flows enough.
- If you’re planning an intercooler upgrade too, check whether the pipe kit is designed to pair with a specific intercooler (Pusher, SPE) before buying the two separately.
As an Amazon Associate and eBay Partner, toptenpick.com earns from qualifying purchases. Prices and availability are subject to change.