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Modified Intercooler

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Old 11-25-2009, 07:02 PM
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Modified Intercooler

I went to Charleston SC this morning and while trying to accelerate on the on ramp to I26 the motor sputtered and blew white smoke again. This also happened a month ago and I pulled the intercooler off and drained about a cup of water out of it. After it did it again today I said that when I get back home I was going to fix this problem or at least make it easier to drain the water. I took the intercooler off and there was more than a cup of water in it. I drained it out and proceeded to install a drain ****. The bottom would be the best place but I would have to weld an aluminum piece to it to add depth for the threads. On the side of the intercooler there is a spot that is thick and low enough for the water to drain out. I drilled out a 7/16 hole, tapped it with a 1/4" pipe tap, placed some thread tape, and tighten the drain **** into the intercooler. So far it works great, just start the engine, open the drain **** 1/2 to 1 turn, and the water pours out as if it was on an air compressor tank.
I can't post the pics but here is a link to my albums.

Ford Truck Enthusiasts Forums - Hardrock_F250's Album: Intercooler Mod 2008 F350 6.4
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Old 11-25-2009, 07:50 PM
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That is great, maybe the mods can add it and the pics to the tech folder as "Intercooler Fix"
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Old 11-26-2009, 01:30 AM
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There is a tsb out for the problem you are describing. If your truck is under warranty I would contact Ford. 08-25-1 12/22/2008 Diesel Engine - White Smoke In Cool Humid Conditions

Here's a link to the actual tsb:

Tsb 08-25-1 - TheDieselGarage.com
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Old 11-26-2009, 07:20 AM
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Originally Posted by mick1955 View Post
There is a tsb out for the problem you are describing. If your truck is under warranty I would contact Ford. 08-25-1 12/22/2008 Diesel Engine - White Smoke In Cool Humid Conditions

Here's a link to the actual tsb:

Tsb 08-25-1 - TheDieselGarage.com
Those that are having problems are not always successful in the new intercooler either. Some still have the issue. It is a design flaw. I am not an engineer but that is my belief.
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Old 11-26-2009, 08:41 AM
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That is great, maybe the mods can add it and the pics to the tech folder as "Intercooler Fix"
Done and done... Great information for everyone
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Old 11-26-2009, 10:18 AM
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HardRock has had the new intercooler fix, but is still getting condensation. This is an excellent fix. Glad to see you got it taken care of.
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Old 11-26-2009, 10:22 AM
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Quote:
Originally Posted by mick1955 View Post
There is a tsb out for the problem you are describing. If your truck is under warranty I would contact Ford. 08-25-1 12/22/2008 Diesel Engine - White Smoke In Cool Humid Conditions

Here's a link to the actual tsb:

Tsb 08-25-1 - TheDieselGarage.com


I had that done the first of this year but when the humidity is high the moisture still collects/condenses in the CAC/intercooler. Now I can drain it out without having to take the unit off. I live in SC and the humidity has been high here for about two months straight.
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Old 11-26-2009, 10:37 AM
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This idea had been shot down previously, with concerns of weakening the intercooler, but it looks like you've managed to do it in a way that addresses this. Great post! Wish I'd just done this instead of going through the TSB hassle.
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Old 11-26-2009, 10:57 AM
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Know if you can figure out how to make the drain automatically dump like my air compressor
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Old 12-21-2010, 06:02 PM
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Quote:
Originally Posted by Maxium4x4 View Post
Know if you can figure out how to make the drain automatically dump like my air compressor
I put a 12 volt air valve on mine to switch 4 . Once a week turn on
(open) with truck off or running to dump water!
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Old 12-22-2010, 09:07 PM
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Do you have any pics of your install?
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