Hi all, last weekend I started the banks intercooler install on my 97 ccld. It took me the entire day to pull everything apart and they were a couple hidden nuts in the back behind the front headlights that were hard to find.

Yesterday I started cutting out the intercooler to piping connection. I use the provided template and taped it up in the area where the illustration shows. That template is very detailed. My primarily used a grinder with a cutting wheel. Had to finish it off with a sawzall. I then added edge guard after priming the bare metal to avoid any rust. I was also able to mount all the bracketry for the intercooler and mount the intercooler.

Today, I started installing the piping. Which I find is the hardest part to get the straps and boots on and everything lined up. It seems like the piping is slightly off and definitely adding Vaseline to the inside of the boots and the inside of the straps to allow adjustments. There are a couple items that are in conflict. There is a, I'm assuming AC line coming from the radiator and the power steering line that route from the reservoir to the pump. Coincidentally I had to replace that line while I was doing this job because it was leaking. Has anybody had these issues? How hot does a turbo side of these intercooler pipes get? I'm concerned that these hoses touching my cause damage. And as you can see the power steering line is very close to the belt. Let me know any thoughts or ideas. Thanks

 

I actually had my belt slice the power steering line on the first 7.3L I installed this on. Had to get a new line and learned quickly to zip tie it up out of the way. Had to clean up quite a bit of ATF from under the hood when that happened.

 

Yes, that is an AC line.

might need a longer power steering hose so you can get more clearance.

 

I ended up pulling the intercooler pipe out. And routed the AC line on the other side and turned the inter pipe at a higher angle, which then pushed up against the AC line going to the cab. I also routed the power steering line around instead of routing next to the belt. The line is just long enough but it wraps around the pipe tight. Surprisingly my s&b intake fits too. At first it seemed like there was no chance it was going to fit. They do hit each other though. I wanted to keep my bracket the bolts to secure the intake boot so I did a little trim job. I don't really like the piping touching hoses considering they do get somewhat hot on the turbo side.

 

Final product. Haven't taken it out yet. That power steering line was leaking. Coincidentally that line was leaking and I put a new one and starting leaking at the steering box connection. I'm wondering it it needs a o-ring because it's tight and still leaking. The reservoir end has a o-ring seal but not the steering box end.

 

Mounted the tranny cooler to the back of the bumper. Had to space the bumper off the frame mount 1/4" with square washers. Not crazy about the tranny cooler mount to the bumper but it fits. I might change it.

 

Looks nice and clean. I dig the big red pipes.

 

That looks great installed there. I always have to take a second look because my setup is different then literally everyone else's.

I agree on the red, really looks sharp.

 

Couple more pics from the initial steps. Installing the piping was the most difficult. The boots and piping do not slide past each other easily. Still haven't figured out the power steering line that wraps too tight around the turbo side pipe.

 

For those who are interested in knowing the difference between no intercooler and the big center cooler. Finally towed with this intercooler installed couple weeks ago. I noticed at least 200° difference and more usable power. I was towing my camping trailer that weighs from 6500 to 7500 lb. Because I was using more power I did notice the transmission kicking into lower gears as I was climbing different hills. I wasn't driving into the mountains or anything but I did take it over some bridges and some steep Short hills. Overall I'm very happy with this particular intercooler and I feel like my truck is more usable when towing. Even when I'm not telling I have more power at my fingertips. I would say next to the Hydra and the injectors the intercooler is one of the best performance upgrades

 

Does anyone feel that adding a drain plug to the bottom of the intercooler is needed?

 

Not read about one being needed.

Think about 400 CFM in a 4 in pipe about 4500 FPM, it going to blow the oil through it once you start making boost at 1500 RPM
An air knife needs about 5k FPM to blow off cutting oil.
Stock turbo make about 800 CFM at WOT