What is involved in removing the intercooler? I want to remove it to clean it out after doing the CCV mod so as to not rrecirculate any oil that may be in it.

 

It's easy, yank out the intercooler tubes. Now just loosen up the coolant reservoir on top of the fan shroud. Pop off the matting that sits on top behind the grill. Remove the brackets holding the radiator, remove the two bolts on each side of the intercooler (top corners). Now pull the radiator forward and pull out the intercooler. It's a tight fit but it will slide right out.

 

It's not difficult at all. I've pulled the basic R&R from a thread I wrote about swapping in a 6.0 IC here:

You don't have to pull the radiator at all. Just remove the top radiator support. First you have to take off the black rubber piece that's between the grille and the radiator support. You might want to get some new plastic body pins that hold it on because you will most likely destroy the old ones when you pull them out.

Take out the 2 radiator support bolts, on the back side of the radiator support beam, near the top of the radiator. Then remove the bolts that hold the radiator support beam. I think there's 4 per side, 2 in front, 2 in back. Then lift the radiator support beam out. It's snug, and you may have to do some prying to get it out.

Once it's out, you should be able to see the intercooler that's directly under it. Remove the clamps and hoses connecting it, if you haven't done so already. Once they're free, the intercooler should just lift right out. The fit between the intercooler outlet and some of the A/C lines & radiator may be tight. I had to loosen the overflow bottle to allow the A/C lines enough room to move so I could get it out.

Installation is reverse of removal.

If you wanted to read the whole thread, here's the link: https://www.ford-trucks.com/forums/4...l-writeup.html

 

I was very suprised how little oil that was in mine when I replaced it, about a 1/8 of a cup. That was with 150K miles. But if you want to do it, this is the basic step that I did mine. If you do it you might as well pick up some coil cleaner or similar and clean the radiator, intercooler and AC condenser. I had a lot of crap in mine.
-Remove the rubber flap that covers the coolers, plastic push-pins hold it in place.
-Remove the grill, 4 top philip screws and the bottm is held in with climps (just pull the grill and they will pop loose).
-Remove the top 2 bolts holding the AC condenser (the condenser will push forward enought to remove intercooler).
-Remove top crossmember, 4 bolts hold it to the body(a rubber mallet and patience is needed to remove and re-install this).
-Remove intercooler tubes and boots.
-Remove intercooler bolts.
-Patience!!!!!!!

I see Jeremy beat me to it, I followed his instructions when I did mine!

 

I guess I may be over estimating the amount of oil in there, if you only got an 1/8 cup out of yours. If it's that little, I may just remove and clean all the boots as planned instead. Thanks for the link Jeremy.

 

personally i would replace the intercooler with a 6.0 if i was going to pull it out and clean it. They aren't that much brand new on ebay. they give a little reduction in EGT, i know jeremy posted some numbers a while back. I did this and for the money i believe it is worth it, wish i could afford a technicooler or any aftermarket cooler but the 6.0 was about all i can afford and only cost about 150 with the boots you need. I did this when i did my ccv mod so i would have brand new cooler when i got ride of the oil problem.

 

I've been looking on eBay for a while now, most I see are used and go for close to $200.