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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
 

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can this mod be done to an Early 99 the same way as described above???
 

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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
 

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Intercooler for my 97?

4cstr said:
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.
 

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Yes you can. Pm me and I will give you a few sites to look at for a IC install
 

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A few more...
 

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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?
 

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I cant see why you could not install a 6.0 IC... The down pipe thing... you cant fit a 5" on a SD only way I could see it on a OBS is cutting the fire wall and making a tunnel... You would gain nothing over a 4" down pipe..
 

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4Cstr, i just finnished my 6.0 install today, other than re-installing the tubes, and i thought it was easier to pull the cross bar that bolts the radiator, intercooler, and evap coil. You may want to add that to the write up as opposed to messing with the fan shroud.

-If it is in the write up, then sorry i missed it, but i dont think i saw it.
 

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6.0 Intercooler for my 97 7.3

I am also looking to install a 6.0 IC on my 97 7.3 I have been looking for some time a good source for the parts. If anyone can direct me to a source I would be much appreciated.
 

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adambomb said:
can this mod be done to an Early 99 the same way as described above???
Yes it can i've recently completed this mod on my early 99 you can do almost any mod on an early 99 the same as a later 99 except turbo tricks the turbos are different i found that out the hard way with a waste gate.
 
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