6.0 Intercooler upgrade started

[Tail_Gunner]

I started my conversion/install of a 6.0 intercooler today. I was considering one of the larger intercoolers that cost $1000 and more, but decided I didn't need one of the pricier ones that much.

I pulled the radiator support's top crossmember out and it allowed the old intercooler to come out in less than an hour. Once I had the old one out, I compared it next to the new 6.0 intercooler:
View attachment 5893


When I tried to installed the 6.0 intercooler, I met up with a small glitch. The routing of the tranny cooler lines interfere with the bottom of the bigger intercooler.
View attachment 5894
So tomorrow, I'll have to get some tranny cooler hose and tubing to re-route the tranny cooler lines to avoid the new intercooler.

One interesting footnote to add: it appears that the sizes of the intake and outlet on the new intercooler is the same as on my OEM early 99 intercooler. So the new adapter connector boot I bought, was for naught.

 

[Tail_Gunner]

It's Done.

I finally got it finished. It took me a few days to get done due to things like rain one day and getting off work late another.

I had obtained a 3.25"x 3.00" intercooler tube connector hose ahead of time. I heard one side of the 6.0 intercooler was larger tube than the OEM 7.3. But that outlet side was the same diameter. But as it turns out, you do need new connector boot. What you need are LONGER connector boots. So I ended up using the new connector boot anyway.

Also, to my surprise, the intake side of the 6.0 intercooler is actually SMALLER than the original one. It is 3" on the 6.0, instead of the 3.25" on the OEM 7.3 version. So instead of being done, I had to go searching for a 3"x3" connector boot. But luckilly, I was able to find locally one albeit a bit shorter than 8" length desired. Then I found out one of my connector boot clamps was too big. So I grabbed a couple of common hose clamps as a temp fix.

Total project cost was about $350 plus shipping/tax. A lot cheaper than the more expensive intercoolers and probably not quite as much of a performance improvement. But AN IMPROVEMENT none the less.

So in summary, if you want to upgrade to a 6.0 intercooler, you will have to re-route tranny cooler lines, get longer intercooler tube connector boots, a 3"x3" & 3"x3.25" both about 8" long and one or two 3" connector boots clamps.

 

[BamaSixGun]

good job kent, nice work

 

[CSIPSD]

I built a drop bracket for the PS and Tranny cooler when I did mine... Easier because I had a welder sitting there... I also cut and extended the IC tube to make up the differance.

 

[powerboatr]

good deal you got it all hooked back up.

and a great price