When you click on links to various merchants on this site and make a purchase, this can result in this site earning a commission. Affiliate programs and affiliations include, but are not limited to, the eBay Partner Network.
Long story short, I hit a deer with my '04 Excursion 6.0 PSD. It damaged the turbo/intercooler tubes. As long as I need new ones, I am getting aftermarket ones. Also figured I will upgrade that entire tract and get a new intake elbow.
I bought this: KC Intercooler Pipe Kit - 6.0 Powerstroke (2004-2007) and not only does the cold side intercooler tube not fit, the intake elbow is COMPLETELY wrong. I did lots of searching online, and every intake elbow I can find that says "2003-2007 6.0" and the like, has this much bigger base plate that is absolutely wrong for my truck.
Someone please help, what in the heck is going on here? And can anyone point me to an aftermarket elbow that WILL fit my 2004 Excursion 6.0 PSD?
Stock intake elbow next to the new (incorrect) KC Turbos one...
Old/stock cold side turbo pipe lying directly on top of the new one. You can see the problem with the angle(s).
Here it is in the install orientation in the engine bay...um, yeah that won't work. What the heck is happening here? Please help, thanks.
OP,
Any chance you can put a caliper or mic on those pipes and tell us what the wall thickness is?
Anyone know why this won't work on an 03?
I don’t have an early ‘04, but after reading a lot on this 6.0 forum my understanding is that device was written out of the strategy and doesn’t really do anything anyway. Late ‘04 and up ONLY have the elbow that’s bolted direct to the intake. I bet once you bolt the new KC elbow directly to the intake everything lines up perfectly. It doesn’t look that far off.
If it's just about that dumb throttle plate adapter, that makes sense. Mine doesn't do anything; no throttle plate inside, and dummy plugs at the electrical connectors.
As for the tube angle, unless it is bent inquire about a replacement. If not you'd be surprised how much "give" the silicone boots have and will naturally conform to the new angle.
You may have bent your core support and the IC is now sitting crroked as well. Pull out the tape measure and start taking reference measurements to get an idea
Yep, that is absolutely the issue with the elbow plate. I went out and looked and yes that 'spacer' part you said to remove, it has the bolt pattern I need on the bottom side where it bolts to the intake.
However...my 'spacer' is slightly different and it has the throttle plate in it...I have a feeling this is going to end badly for me.
Sounds good but what do I do if my throttle plate adapter actually has the throttle plate *in* it? Am I hosed? Hehe I love this truck so much but why does it have be an early this or a late that with apparently all kinds of weirdness that makes everything WAY more hassle than it should be.
I did not know any of this info regarding this issue. Dang it.
Ever since I posted I've been reading and researching (not long). But am I correct that the butterfly plate in question is NOT a throttle plate but actually for some EGR function? I will have to look at my records as it's been awhile, but IIRC the EGR delete was done to my truck.
So all those wiring harness connections I just disconnect and leave off??? Heh that doesn't seem right, but I am 100% not aware of this process as well. Won't all kinds of codes get thrown?
My Ex is mechanically stock (other than the custom PTO generator setup, and 99% sure EGR delete), i.e. no tuner or anything like that to address a possibly avalanche of codes... ??
Just unplug the harness from the throttle body and see if you get any codes or a CEL. I'm guessing not.
If you get a CEL from removing the throttle body, you can get an original 03 tune that will clear it up if you don't have it already. I am running VXAM7N2 and I have no CEL. What I do have is a P0401 (which is typical egr delete code) and a P0404 that just came up that I need to look into.
Yeah I have calipers, I will get that info later for you. Why does the wall thickness matter? Other than a better or worse quality product I mean.
I just want to compare to other CAC pipe offerings. I had a Mishi CAC pipe/boot kit on my last 6.0L and the walls of the pipes (aluminu) were so thin, the clamp would turn the end of the pipe into an oval under their recommended clamp bolt torque of only 32 lb-in. IIRC the walls of their pipes were 0.060".
Rezvani's Latest Post-Apocalytic Monster Is a Ford F-150 Raptor Underneath
Slideshow: Called the Fortress, the 850-horsepower pickup combines Raptor underpinnings with military-inspired features, survival equipment, and a starting price of $285,000.
