6.0 Intercooler Install - TheDieselGarage.com
TheDieselGarage.com
 

Home Forum Who's Online Today's Posts Vendors Advertise
Go Back   TheDieselGarage.com > Ford Diesel & Truck Discussions > Ford - Modification instructions, Product installs and Tech Articles

Thread Details Posted by 4cstr, this thread has received 18 replies and been viewed 11559 times.

TheDieselGarage.com is the premier Forum on the internet. Registered Users do not see the above ads.
Reply
 
Thread Tools Display Modes
Old 12-16-2005, 08:30 AM   #1
4cstr
Guest
 
Posts: n/a
Points: 0 [Check]
6.0 Intercooler Install

With the EXPERT help of the guys from the Western New York Powerstroke Club, Thanks Gar, Jim, Jeff and Kory, I just finished the 6.0 intercooler.

The new intercooler is 31% bigger.

Original 30x18x2
6.0 30x21x2.25

It was easier than I thought, much of the time was on the fly engineering. I have not fired it up yet so I have a few concerns I will address.

INSTALLATION

Either drain radiator or drain enough to remove upper radiator hose
Remove over flow tank on top of the radiator
remove all radiator and AC condensor mounts but do not remove either
Remove upper radiator hose.
Remove bolts holding fan shroud
I have a stick so you might have to move the tranny cooler on an auto??

Remove 2 bolts holding Intercooler and hoses connecting to pipes

Tilt back the radiator as far as possible and pull the intercooler out. This will take some manuevering to get it clear of the AC lines(removing the condensor mounts allows moving of the lines) but it will come out. Better to have 2 people one at each end.

The new intercooler is 1/4 inch thicker so you will have to get the fan shroud in just the right spot and the radiator a little farther back to get the new one in place. again 2 people for this. Bolts right up to the original mounts.

NOW THE FUN PART

The intercooler tubes do not fit!

This took some time but our fearless leader Gar Hanson figured it out.

The inlet is smaller on the new intercooler, same size 3" as the intercooler tubes. The outlet is the same size as the original.

The inlet and outlet are also an inch shorter so we needed to fill this gap and figure out the size problem.

The solution was simple. you need 2 napa intercooler hoses Part number 1701 and 1740 and 2 extra clamps

Cut off 2.5 inches of the oultet pipe near the intercooler, passenger side of the truck, save this short piece. attactch the 1701 hose on the shortened intercooler pipe, attatch the 2.5 inch piece you cut off to connect the new hose from NAPA to the stock blue hose. This blue hose fits on the new intercooler. you use the new NAPA hose to add 1/2 to 1 inch of length. Cutting the pipe and reconnecting it with a 1/2 inch or so gap gives you the extra lenght you need.

On the other side the NAPA hose 1740 adds the extra length needed.

Thighten it all up! put the other parts back in place!

WFTREE
  Reply With Quote
Sponsored Links
Advertisement
 
Old 05-18-2006, 06:44 PM   #2
adambomb
Junior Member
 
adambomb's Avatar
 
Join Date: Dec 2008
Posts: 211
Points: 5,032
Thanks: 34
Thanked 16 Times in 15 Posts
Question

can this mod be done to an Early 99 the same way as described above???
adambomb is offline   Reply With Quote
Old 05-24-2006, 06:04 AM   #3
onebadf150
TDG MAFIA MEMBER #85
 
onebadf150's Avatar
 
Join Date: Dec 2008
Location: New Orleans
Posts: 1,683
Points: 26,381
Thanks: 46
Thanked 54 Times in 40 Posts
Wait I don't understand you had to cut the hot side intercooler pipe b/c it was to long, doesn't make sense I haven't heard of this problem yet and I've read alot of post concerning this install, I not saying its not a problem and I'll watch for this when installing mine, thanks for the write up and part #'s :Thumbup:

Nick
onebadf150 is offline   Reply With Quote
Old 05-24-2006, 12:30 PM   #4
hhrecovery
MAFIA #8
 
hhrecovery's Avatar
 
Join Date: Dec 2008
Location: Pulaski, VA
Posts: 5,567
Points: 61,418
Thanks: 104
Thanked 223 Times in 209 Posts
Images: 1
Take some pics when you do yours so that it will be more helpful...
__________________
Aaron - 2004 F350 "Offroad Edition"

2003 F250 "Pulling Truck"
hhrecovery is offline   Reply With Quote
Old 10-23-2006, 04:59 AM   #5
CustomBaggers
NativeCustomBaggers
 
Join Date: Oct 2006
Posts: 5
Points: 28
Thanks: 0
Thanked 0 Times in 0 Posts
Intercooler for my 97?

[quote=4cstr]With the EXPERT help of the guys from the Western New York Powerstroke Club, Thanks Gar, Jim, Jeff and Kory, I just finished the 6.0 intercooler.


I heard I can adapt a 6.0 intercooler to my 97 powerstoke. Can this be done? If so, which is the best year intercooler to use and can I use all the tubing or does it have to be custom made? If I can't adapt one, which is the best brand to use for my 97? Thanks. Paul.
CustomBaggers is offline   Reply With Quote
Old 10-23-2006, 03:29 PM   #6
CSIPSD
Senior Member
 
CSIPSD's Avatar
 
Join Date: Sep 2005
Location: Bend OR
Posts: 6,337
Points: 28,940
Thanks: 19
Thanked 78 Times in 70 Posts
Yes you can. Pm me and I will give you a few sites to look at for a IC install
__________________
01 F-250 SC PSD,210k,16 Isspro Gauges, AFE-2,CCV Mod,IAH delete,map reg,Modded H2e, 6.0 IC, GTS Hybrid injectors, Studs, 910 Valve springs, Forged rods Water injection,Swamps tuned, MBRP 4" dual's, Aero, 6" tip's, 100 axl tank, 4" Revtek lift, 37-14.50-17 TOYO MT's 469hp and 1068tq...

ISSPRO PERFORMAX GAUGES
CSIPSD is offline   Reply With Quote
Old 11-07-2006, 02:03 AM   #7
CSIPSD
Senior Member
 
CSIPSD's Avatar
 
Join Date: Sep 2005
Location: Bend OR
Posts: 6,337
Points: 28,940
Thanks: 19
Thanked 78 Times in 70 Posts
I did the install this weekend, here are a few pic's I took...


http://www.thedieselgarage.com/galle...c=9&userid=932
Attached Thumbnails
Click image for larger version

Name:	6.0 installed.JPG
Views:	265
Size:	61.9 KB
ID:	7209   Click image for larger version

Name:	Condenser brackets going back in.JPG
Views:	170
Size:	75.4 KB
ID:	7210   Click image for larger version

Name:	drop bracket for Tranny and PS coolers.JPG
Views:	167
Size:	47.0 KB
ID:	7211   Click image for larger version

Name:	dropped in.JPG
Views:	146
Size:	66.0 KB
ID:	7212   Click image for larger version

Name:	extended tube.JPG
Views:	232
Size:	45.1 KB
ID:	7213  

Click image for larger version

Name:	IC pipes removed.JPG
Views:	200
Size:	66.5 KB
ID:	7214   Click image for larger version

Name:	lowering bracket.JPG
Views:	132
Size:	37.0 KB
ID:	7215   Click image for larger version

Name:	new AC condenser.JPG
Views:	167
Size:	68.0 KB
ID:	7216   Click image for larger version

Name:	removeing core support.JPG
Views:	135
Size:	56.0 KB
ID:	7217   Click image for larger version

Name:	rubber valance removed.JPG
Views:	151
Size:	62.2 KB
ID:	7218  

__________________
01 F-250 SC PSD,210k,16 Isspro Gauges, AFE-2,CCV Mod,IAH delete,map reg,Modded H2e, 6.0 IC, GTS Hybrid injectors, Studs, 910 Valve springs, Forged rods Water injection,Swamps tuned, MBRP 4" dual's, Aero, 6" tip's, 100 axl tank, 4" Revtek lift, 37-14.50-17 TOYO MT's 469hp and 1068tq...

ISSPRO PERFORMAX GAUGES
CSIPSD is offline   Reply With Quote
Old 11-07-2006, 02:05 AM   #8
CSIPSD
Senior Member
 
CSIPSD's Avatar
 
Join Date: Sep 2005
Location: Bend OR
Posts: 6,337
Points: 28,940
Thanks: 19
Thanked 78 Times in 70 Posts
A few more...
Attached Thumbnails
Click image for larger version

Name:	size compare.JPG
Views:	222
Size:	63.4 KB
ID:	7219   Click image for larger version

Name:	top view size.JPG
Views:	151
Size:	69.1 KB
ID:	7220  
__________________
01 F-250 SC PSD,210k,16 Isspro Gauges, AFE-2,CCV Mod,IAH delete,map reg,Modded H2e, 6.0 IC, GTS Hybrid injectors, Studs, 910 Valve springs, Forged rods Water injection,Swamps tuned, MBRP 4" dual's, Aero, 6" tip's, 100 axl tank, 4" Revtek lift, 37-14.50-17 TOYO MT's 469hp and 1068tq...

ISSPRO PERFORMAX GAUGES
CSIPSD is offline   Reply With Quote
Old 12-04-2006, 07:52 PM   #9
southernlx
Junior Member
 
Join Date: Dec 2006
Posts: 1
Points: 10
Thanks: 0
Thanked 0 Times in 0 Posts
INteresting.
southernlx is offline   Reply With Quote
Old 12-23-2006, 05:52 PM   #10
BryanC7.3
Junior Member
 
Join Date: Dec 2006
Posts: 1
Points: 10
Thanks: 0
Thanked 0 Times in 0 Posts
Can 6.0L intercoolers be installed in my 1997 F-250? If so plaese can anyone get me some information? And I was also curious of whether you can put 5" downpipes on first generation torbo powerstrokes?
BryanC7.3 is offline   Reply With Quote
Sponsored Links
Advertisement
 
Reply


Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Forum Jump

New To Site? Need Help? TDG Specials

All times are GMT. The time now is 11:50 PM.



Powered by vBulletin®
Copyright ©2000 - 2014, Jelsoft Enterprises Ltd.
DTO Garage vBulletin Plugins by Drive Thru Online, Inc.
vB.Sponsors
vBCredits v1.4 Copyright ©2007 - 2008, PixelFX Studios