I am the lucky dog who got the Ford 6.0 intercooler from indebt. It will be going into the shop tomorrow for repair...so as many of you know I live in "the middle of nowhere" and I'd like to pick up the parts when I drop the intercooler for repair. I have an early 99 and was wondering if anyone has a parts list or a "how-to" that someone has put together. Thanks again George! Thanks in advance for any and all info!

 

http://www.puredieselpower.com/catal...cPath=30_32_44

You are going to need the hoses. Best you measure the diameter before you order them. Other than that it was straightforward.

 

damn you got it already, that was fast, good luck I will also be doing mine tomorrow LOL, im gonna use his parts suggestions.....


heres the post from MECH2161 from a while back.....

Here are some posts from the other site that might help.
The inlet is smaller on the new intercooler, same size 3" as the intercooler tubes. The outlet is the same size as the original.

The inlet and outlet are also an inch shorter so we needed to fill this gap and figure out the size problem.

The solution was simple. you need 2 napa intercooler hoses Part number 1701 and 1740 and 2 extra clamps

Cut off 2.5 inches of the oultet pipe near the intercooler, passenger side of the truck, save this short piece. attactch the 1701 hose on the shortened intercooler pipe, attatch the 2.5 inch piece you cut off to connect the new hose from NAPA to the stock blue hose. This blue hose fits on the new intercooler. you use the new NAPA hose to add 1/2 to 1 inch of length. Cutting the pipe and reconnecting it with a 1/2 inch or so gap gives you the extra lenght you need.

On the other side the NAPA hose 1740 adds the extra length needed.

Thighten it all up! put the other parts back in place!


also http://www.dieselpowerproducts.com/air sells tubes and boots that make the swap really easy and quick so you might check them out, it cost a little more than the napa boots. I guess it just comes down to how much money you want to spend to make is easier. I also belive a few people have put the upgraded banks 6.0L intercooler in a 7.3l for even better cooling. LIDP make a upgraded 6.0L intercooler with 7.3l alum. end tanks I belive, just think of how big of an intercooler that would be, but I am not sure if there 6.0 cooler fits in a 7.3 without mods

 

I'd get the hoses to make it easier. First measure the inlet and outlet size to be absolutely sure before ordering. I didn't want to save the few bucks and have more cutting and pasting.

 

I got one of the eBay 6.0 intercoolers from Banks and went ahead and bought two new hoses so I would not have any length issues. Unfortunately, I probably won't get it installed until sometime this summer due to pressing family matters that seem to be consuming most of my time now. I do plan on a write-up when done though............

 

Hope all is well guzzle, and we look forward to another excellent writeup.

 

No, all is fine. Just moved my elderly parents up from Arizona because they are just getting to old to be 1000 miles from family. Trying to get a house fixed up so they can move into it.

 

Good to hear, my folks are going by the wayside. Sorry for the hijack. Keep them as close as you can. Got mother in law and my mother left now.

 

I just cut and extended the pass side tube... but I have a welder in the shop soo... makes it easy... and I got the new boot for the drivers side...

Today I am removing my IC tubes and welding a bead around them to keep them from blowing off... I am tired of crapping myself when I get that loud POP at about 38#'s boost!!! Gurrrrrr.

 

I found a good write-up on "another" site (with lots of pictures)...I'm never sure if we are suppose to, or not, post a link to a competitor...to be safe I am not going to. If you want the link, just pm me.

Another question...Does the stock early 1999 intercooler have aluminum endtanks or are they plastic like the 6.0?

 

My 01 has aluminum endtanks

 

The 2002 MY was the start of the plastic end-tank deal.