Tech Tips, Anyone???

6.0L Intercooler Into Old Body Style

Posted July 16 2009 11:45 AM by Mike McGlothlin
Filed under: What's New, Tech Tips

Anyone out there ever put a 6.0L intercooler in their old Ford Power Stroke?

I’ve got one and am going to begin the install soon. Just thought I’d start gathering any info I can to help me try to get all the (right) parts I need. I'd like to make it go as smooth as possible. At this point, I think running the plumbing will be the hardest part for me, and there are retrofit kits out there…

Anyone out there ever done this?

I think it’ll be a good budget-oriented way to cool off your old body style Ford, or even your Super Duty 7.3L. Heck, you can pick up the 6.0L intercoolers for next to nothing, so what’s there to lose?

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Reader Comments:

1. Nothing but EGTs.

jason.thompson - Posted July 16 2009 02:08 PM

2. i think it would get alot more air if you mounted it in FRONT of the grill. custom "quick release" zip ty mounting. just throwin this out there. pvc plumbing would also help in cooling

linmup - Posted July 16 2009 06:22 PM

3. I think I've seen it done.

If you just get all the same bracketry to do a 7.3 Intercooler, which I KNOW has been done, I'm pretty sure most of the mounts are the same and you'll only need the adapter boots.

I haven't done it. But that's how I would do it if it was mine.

theSLEEPER444 - Posted July 17 2009 08:22 AM

4. I installed one in my 95' a couple years ago when I did my cummins swap. There is a little work you will have to do. I have a few pics I can e-mail you if you would like. PM me and we will go from there.

9598FORDGE - Posted July 17 2009 05:14 PM

5. Very good info, thanks. And PM sent...

Mike McGlothlin - Posted July 18 2009 11:09 AM

6. Don't mind all the welds along the top of the core support. It was much easier to cut the center of the core support out for the engine swap, especially since the powerstroke had already cracked it in a number of places. The welds have since been cleaned and painted. Built new condensor brackets to bring bottom to where it has minimal clearance on the radiator.

http://i197.photobucket.com/albums/aa261/hisawhay/IMG_0805.jpg

9598FORDGE - Posted July 19 2009 07:09 AM

7. Finished mount (edit)

ok cancel
2- 1" pieces of square tubing welded to gether with a spacer in between to get the bottom of intercooler to tightly slide in upon installation and to clear the condesor. Don't make too much clearance though or you won't be able to install the body work under the headlights. You will also have to cut your hood latch bracket just below the mechanism to clear the top of intercooler.

http://i197.photobucket.com/albums/aa261/hisawhay/IMG_0806.jpg

9598FORDGE - Posted July 19 2009 07:12 AM

8. Intercooler installed for fitting

You can see how the intercooler fits, in this pic I still need to drill holes for the upper mounts. I now have a bolt with a rubber bushing similar to the factory upper mount for the upper brackets.

http://i197.photobucket.com/albums/aa261/hisawhay/IMG_0807.jpg

9598FORDGE - Posted July 19 2009 07:15 AM

9. Those are the three pics I have for installing the intercooler. The only complaint I have is the whole front end of the pickup had to be removed to install the banks intercooler about a year ago.

9598FORDGE - Posted July 19 2009 07:21 AM

10. Sweet, thanks for your time and comments.

Mike McGlothlin - Posted July 19 2009 12:50 PM

11. What you need to do is remove your fan cause you don't need it. We found out that at 35 mph ur fan stops working anyways and the powerstroke runs pretty cool. SO once u have romved the fan then u can put the radiator back enough to fit the intercooler in there. Thats how I did it on a customers trucks. And we tested the truck in bumper to bumper traffic to make sure of over heating and the trucks didn't even go up 50 degrees more then already running temp.

cummins517 - Posted July 21 2009 07:25 AM

12. Don't remove that fan in southern california, it was 118 degrees down here today. you might be able to do that somewhere else, but you will be buying a new engine.

linmup - Posted July 21 2009 03:06 PM

13. i have a 2006 chevy 3500 dually diesel 4 door and i want to put stacks on it but i dont want to do what everyone else does and go through the bed i want to go up the side of the truck but i want to see some pictures or something giving me and idea of how to do this if anyone has any ideas please let me know thanks

dude726 - Posted July 22 2009 09:38 PM

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