Ford 6.0L intercooler install in '92-'96 body

[Traveler]

Just for Chuck.

I bought this intercooler a couple years ago now and finally getting it installed.

At the time it was the most efficient setup. Better cooling than the 7.3L coolers and supposedly as good as the Banks, or hypermax setup. Now they have the spearco intercooler that might be more efficient. Not sure.

There are a couple companies that make complete kits for this year truck. I don't know them all yet. Not even going to try and list them.

When I went in search of install articles I was very disappointed, Some write ups had okay instructions and poor pictures, then some had better pictures and little or no write up. There were some questions I just could not get clear answers too.
I will try to do a little better.

One thing I noticed on the different installs is that people seem to either be mounting them at different heights, or just not paying attention to where they are putting them. Maybe they just don't care.

This is of course on a 4x4, 2 wheel drives have a sway bar that has to be moved from what I have read.

I believe the 7.3L intercooler is also smaller and will eliminate that problem.
The 7.3L intercoolers came in two styles, early ones had plastic tanks that cracked over time. The aluminum ones were much better. Then came the 6.0L and it only had plastic tanks and from what I have heard has been holding up just fine.

I was worried about the tranny cooler mounting, from what I had read it was a nightmare, but really wasn't a big deal when it came down to it.

Some welding will be required to make the lower mounts. Beyond that a drill, and a sawzall is about the only tools you need over basic hand tools.

The entire photo album is here intercooler install

Before. You can see the location of the tranny cooler before the install.


Strip the front end. You need to remove everything. It isn't as hard as you think it is, just a pain to get to some of the screws.



Remove the lower AC condesor mounts.




Flatten them out.


Cut them



Re drill a hole in them. I went ahead and slotted it like it was before. Just quicker and easier to reinstall that way.




Reinstall them.



There are different versions of how to do the radiator/hood latch support. I took the original out of there and flattened it in a press.
I have seen other guys cut this off and weld a piece of strap in.



Reinstall. I had to cut about 1/2 inch off the botton, and re drill a new hole for it. The bottom is also now mounted inside the lip of the lower radiator support, instead of on the stud on the outside.


Start test fitting, trying to figure out where the tubes will stick through at.


Mark the holes where you need to cut. One thing I didn't see clearly mentioned in other writeups, you have to cut into the flanges on the radiator and lose the lower mounting holes. Moving them up a couple inches.
Not a big deal as the radiator is mounted securely at the bottom as well.

Rough marker outlines



Hack it out of there.





Test fit for any additional trimming.