Intercooler install
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Senior User
Joined: Sep 2010
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Intercooler install
Started my 6.0L intercooler install yesterday.
Got the holes cut, cooler mounted and lower brackets welded up.
Didn't run into ANY of the issues that I've read in any write ups. Not sure why my situation is different.
Didn't need to move the a/c condenser towards the engine.
Didn't need to flatten out the bracket that goes from the hood latch to the bottom of the rad support either.
The cooler-side clamps will be accessible from the front when the grill is removed. So like 4-6 screws and the grill is off and you can reach in there to get a 1/4 ratchet on them.
Basically use this guys thread as reference: 6.0L intercooler install in '92-'96 body
I have a bunch of pics, just have to get them on here. Will take more through the day (today) as I finish it up. Piping will be on a later date.
Got the holes cut, cooler mounted and lower brackets welded up.
Didn't run into ANY of the issues that I've read in any write ups. Not sure why my situation is different.
Didn't need to move the a/c condenser towards the engine.
Didn't need to flatten out the bracket that goes from the hood latch to the bottom of the rad support either.
The cooler-side clamps will be accessible from the front when the grill is removed. So like 4-6 screws and the grill is off and you can reach in there to get a 1/4 ratchet on them.
Basically use this guys thread as reference: 6.0L intercooler install in '92-'96 body
I have a bunch of pics, just have to get them on here. Will take more through the day (today) as I finish it up. Piping will be on a later date.
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Senior User
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In the pic below it shows how high I mounted the cooler, much easier to drill and attach the rubber mounts at this location versus lowering it. Another reason is if the cooler was lower then this, the nuts for the bumper would have been hard to get on the studs on the bumper.
Laughing Gas
Joined: Dec 2005
Posts: 1,087
Likes: 189
From: Reno, NV
Nice job! Great pics too. IMO, you mounted it in the perfect location. I mounted mine the same as the fourdoorbronco write up. I probably did need to mash the support, but did. With yours mounted 2" higher, it's spaced out towards the front more, so you have even more clearance.
Thanks for sharing, reps sent!
Thanks for sharing, reps sent!
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All together...
Nice tight fit
This is my F up....
This is the corrected way. Had to go to the junkyard and get another to replace the one I messed up.
This is how I reached the cooler clamps, just a 1/4" extension. Granted... the grill has to come off to do this. But that is only 5 screws.
Nice tight fit
This is my F up....
This is the corrected way. Had to go to the junkyard and get another to replace the one I messed up.
This is how I reached the cooler clamps, just a 1/4" extension. Granted... the grill has to come off to do this. But that is only 5 screws.
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FOREIGN GURU
Joined: Jul 2006
Posts: 7,655
Likes: 7
From: Celaya, Gto. MX
Started my 6.0L intercooler install yesterday.
Got the holes cut, cooler mounted and lower brackets welded up.
Didn't run into ANY of the issues that I've read in any write ups. Not sure why my situation is different.
Didn't need to move the a/c condenser towards the engine.
Didn't need to flatten out the bracket that goes from the hood latch to the bottom of the rad support either.
The cooler-side clamps will be accessible from the front when the grill is removed. So like 4-6 screws and the grill is off and you can reach in there to get a 1/4 ratchet on them.
Got the holes cut, cooler mounted and lower brackets welded up.
Didn't run into ANY of the issues that I've read in any write ups. Not sure why my situation is different.
Didn't need to move the a/c condenser towards the engine.
Didn't need to flatten out the bracket that goes from the hood latch to the bottom of the rad support either.
The cooler-side clamps will be accessible from the front when the grill is removed. So like 4-6 screws and the grill is off and you can reach in there to get a 1/4 ratchet on them.
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Senior User
Joined: Sep 2010
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Here's some pictures of the piping work. Started on the cold side.
I started with a new flange and a SD clamp (wider then the OBS clamp)
This was my first obstacle, the A/c line. I couldn't 90 up like I had wanted to.
Here is the small hole I wanted to run through.
Coming out of the coupling on the cooler, I used a 45
Kind of a BIG jump forward. But here's the finished piece all tacked up minus the piece coming off the cooler.
Here's the new plenums mocked up on the bench.
Sooooooooo here's the question for you.... which one to use? The left one will look cooler and flow better, but not hold the clamps on as well as the right one.....
I started with a new flange and a SD clamp (wider then the OBS clamp)
This was my first obstacle, the A/c line. I couldn't 90 up like I had wanted to.
Here is the small hole I wanted to run through.
Coming out of the coupling on the cooler, I used a 45
Kind of a BIG jump forward. But here's the finished piece all tacked up minus the piece coming off the cooler.
Here's the new plenums mocked up on the bench.
Sooooooooo here's the question for you.... which one to use? The left one will look cooler and flow better, but not hold the clamps on as well as the right one.....
Hotshot
Joined: Jul 2003
Posts: 12,177
Likes: 40
From: Newport, WA
Nice work! I think either of the Y pipes will work just fine, toss a coin and choose one. I'd ask you to send me the one you don't use, but you had to go all over achiever and swap to SD plenums 
Elder User
Joined: Oct 2004
Posts: 782
Likes: 1
From: Olympia, WA
Looks good. I mounted mine probably another inch or two higher than you did and cut the split ears off of the top mounting tabs and just drilled a new hole. Doesn't poke up through the top trim that way. I also cut a bunch off of that bracket that used to hold the intake CCV section, that makes the hot side pipe routing a lot easier between the AC compressor and the intake tubing.