I just did the 6.0 intercooler swap on my early 99. The install took about two and a half hours and other then a clamp issue the install went very good. I did a few test runs prior to the swap to get a EGT reading at WOT , pre and post install. I am seeing a reduction of my egt at wot of about 100 degrees +/-. That makes this mod a very worthwhile mod.

Parts needed
1. 6.0 intercooler. #4C346K775 BCA
2. 3.25" X 3" X 8" Intercooler_transition_hose.
3. 3" X 3" X 8" Intercooler_hose_coupler.
4. 3.25" boot clamp # 6C3Z-6K786-EA
5. 3" boot clamp X 3 pieces #1C3Z-6K786-CA
6. Push pins #N806113-S

Tools needed
1. Metric socket set with extensions.
2. Small pry bar.
3. Rubber mallet.
4. Coffee can.
5. 6 Rags.
6. Beer holder.

Install Procedure
1. Remove the rubber upper radiator air deflector. You will destroy the push pins. Be careful with the pins located on the plastic grill as you don't want to crack it.
2. Remove radiator support bolts and grille opening support bolts. 7 bolts / 8mm socket.

3. Remove jack handles and set aside, remove coolant reservoir coolant retaining bolts. 4 bolts / 8mm socket. Do not remove coolant reservoir, this step just makes it easier to install passenger side intercooler boot later.
4. Remove battery cable from radiator support beam. inspect cable for worn spots. leave loose. 3 grey push pins/ these will remain on cable.
5. Remove intercooler retaining bolts. 2 bolts / 10mm deep socket.

6. Remove air deflector push pins that are attached to radiator support beam.
7. Remove radiator support beam. Once bolts are out use small pry bar to lift up driver side of the radiator support beam. It will take a bit of wiggling and a couple of swear words but she will come out. 12 bolts, six each side. 4 bolts / 8mm, 8 bolts 13mm.



8. Loosen upper intercooler pipe boot clamps and pop out pipes from upper boots. 2 clamps / 1 each side.
9. remove plastic air induction piece from battery box. Will come off with some wiggleing.
10. Loosen intercooler and lower intercooler pipe clamps. 4 clamps / 2 each side.
11. Remove intercooler boots from intercooler.
12. Remove 7.3 intercooler. Lift straight up, air conditioning lines may have to move a bit but she will come out.
13. Remove lower intercooler boots and clamps. 2 boots / 1 each side, 4 clamps/ 2 each side.
14. Inspect front of radiator. If it needs some cleaning place rags in intercooler pipes prior to cleaing with air and or water.
15. Place new intercooler boots on intercooler pipes with clamps loosened. the 4 clamps should be positioned so that the nuts will be on the engine side of the boot, not the fender side, it will make it much easier to tighten em' down.
16. Place 6.0 intercooler in position, make sure it is not resting on tranny cooler.
Automatic owners may have to relocate tranny cooler an inch or so.

17. Reverse order of install, EXCEPT THE FOLLOWING. Leave boots and clamps loose until everything else is complete.
18. Remove rags from intercooler pipes. Do a rag count now.
19. Place intercooler boots on intercooler and tighten clamps. 2 clamps / 1 each side.
20. Replace upper end intercooler pipe back into boots, adjust for clearance and tighten clamps. 2 clamps / 1 each side.
21. Tighten lower pipe boot clamps. 2 clamps / 1 each side.

You are done! Fire her up and take her for a test spin. Make sure you take your tools with you in case you need to re-tighten a boot clamp, don't ask.

6.0 intercooler on left, 7.3 intercooler on right.


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Outstanding Jeff. Thanks for the pics and all the info that you gave!
Reps sent!

 

Jeff,

Very professional write-up with pics and diagrams. Helluva Job. Reps to you.

And I won't ask. I blew a boot at IC after turbo upgrade. Sure can blow some mean smoke with zero boost.

 

Very nice writeup. That's exactly how I installed mine, including the "rag count"... lol.

The temp difference at WOT of 100 degrees is right in line with my results too.

 

Thanks guy's. One of our diesel club members had the 6.0 intercooler in his shop. It is too big for what he needed it for but the 7.3 intercooler will work, so we just traded. Gotta love a cheap mod!!

 

Nice write up on the install.I have this mod. on the tado list.

 

Nice write up! Marking it for future reference.

 

Great write up Jeff! Reps given!

 

Great Write up Jeff, i did the same thing

Ken

 

Great write up. I might need this down the road. BTW where did you get the Parts needed..

1. 6.0 intercooler. #4C346K775 BCA
2. 3.25" X 3" X 8" Intercooler_transition_hose.
3. 3" X 3" X 8" Intercooler_hose_coupler.
4. 3.25" boot clamp # 6C3Z-6K786-EA
5. 3" boot clamp X 3 pieces #1C3Z-6K786-CA
6. Push pins #N806113-S

 

Wow this is saved in my SD Tech articles great write up.

 

Good darn write up. Reps to ya

 

Very good write up, you outlined everything needed, props to you sir!