Compression Ignition Addict
Join Date: Jun 2011
Location: Colorado Springs
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Oil inside the boots to intercooler is normal. The oil will degrade the boots and cause them to either split and leak, or just come off under boost. Totally normal since the CCV is vented into the turbo intake. My turbo to intercoller pie would have oil laying in it prior to rerouting the CCV.
Best bet is to reroute the CCV (there is a fellow on this forum who has one for about 100$), or just do a reroute on your own. You will need to repalce the boots, as the oil has ruined them, and they will continue to fall apart even if you clean the oil off of them.
Other choice would be to replace to boots every 100k miles (or however long they have lasted for you...)
2005 F-250 6.0L, crew cab, long bed 4x4
completed in 2011: STC update, new IPR, BPD EGR cooler, oil cooler rebuild, 6.4 banjo bolts, blue spring update, SCT X3, Insight CTS, 58V FICM, CCV Mod, DIY coolant filter (now gone)
, refinished turbo
2012: ARP headstuds, OEM gaskets, standpipes and dummy plugs
2015: XDP coolant filter