intercooler pipes
Fleet Mechanic
Joined: Oct 2003
Posts: 1,764
Likes: 0
From: CentralEastern Utah
I got one on my 96. I bought the GTS kit to install it. As FormanES said the only thing the 6oh cooler needs different is a 3-3.25" boot for the one side. Ya can get it from Ford. Just specify that ya need a IC boot for the right(passanger) side for a 6oh powerstroke. If your 2wd the sway bar need to be moved also, but no trouble if your 4wd.
Logistics Pro
Joined: Jul 2001
Posts: 4,137
Likes: 41
From: Marble Falls, Texas
On mine I added 3" to the drivers side pipe at the turbo. The passenger side was a little more difficult. I used the stock pipe from the intake spider all teh way to the second bend. Then I used 2 3" 90* bends one long, one short to make an S to get it to the cooler and then welded the stock end on the last 90* bend. There are pictures and writeups in my gallery.
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Freshman User
Joined: Feb 2007
Posts: 44
Likes: 0
From: Almont, Mi
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Postmaster
Joined: Jan 2004
Posts: 3,207
Likes: 0
From: Kearney, Nebr
RubberDuck, does you hot side fit up perfectly with the 3 inch extension. I did mine that way and the pipe doesn't sit properly with the hoses. It's about an inch off.
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Logistics Pro
Joined: Jul 2001
Posts: 4,137
Likes: 41
From: Marble Falls, Texas
It's not perfect, but it's pretty close. But I know what you are saying. I think my lack of being able to cut it straight with the chop saw saved me there. It looked pretty straight, but I think I just got lucky cause it fit's really good in my opinion. Most likely I cut it crooked, and got lucky when I welded it together. Because I wasn't looking for an angle IIRC.
