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

 

That is great, maybe the mods can add it and the pics to the tech folder as "Intercooler Fix"

 

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.

 

Done and done... Great information for everyone

 

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.

 

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.

 

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.

 

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!

 

Do you have any pics of your install?