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

[Traveler]

Start mounting it up. I first shimmed it in place. I set the lower mounts on 3/8 drive deep sockets seemed to be pretty close.
The upper mounts are vibration dampners I bought from Gringer, I have read where guys used old shock bushings. It is really the same thing.




Start building your lower mounts. I used a piece of 1.5" angle, 1" box tubing, and a piece of strap. Clamped it all together and welded it up.
There are other ways to build the lower mounts, I like this because it holds the intercooler tight and the mounting bolts are easy to access.



Tack it together and test fit it.


At this point I took it to the wash bay and cleaned everything up. Cleaning the radiator and condensor. Then I painted any bare metal to prevent rust. I also painted the frame horns.


Slip the boots on your intercooler. I used 2 3"x3" boots with constant torque clamps. You need to install the clamps now because there is no room to tighten them later.

The intercooler has what is now the outlet size of 3 1/4" There is a boot made just for that, but I did not have any trouble slipping the 3" boot over it.


Install it. You can see how the clamps are hidden. I had to remove it and turn one clamp a little so it wouldn't rub.




Last thing was the tranny cooler. I had seen where guys hung it off the header panel, bolted it to the bumper. I didn't like any of that. So I took a piece of 1" angle, cut it back a little and bent it to lay flat.
I drilled it so the bumper mounting bolts will hold it in place in stead of drilling new holes.




Placed the tranny cooler. I centered it, I thought it would look better than off to one side.
Bolted it up to the angles.


To hold the whole assembly in place while I installed the bumper, I used a pop rivet on the upper angle.


Re run all of your electrical and tranny cooler lines now.


I have seen the hood latch bent different ways. I simply bent the tab up just a little. It still looks factory.



I still had the rubber flap below the radiator. I reinstalled it. It helps direct air flow through the tranny cooler, intercooler and radiator. It also helps keep and mud from splashing up in there.
I had to trim it at the bottom to fit.



Start installing the front end sheet metal.
The header panel has this little tab that needs to be removed. Not sure why it was there.



Hopefully you have been checking and rechecking your clearances along the way. It is a tight fit.