BearKiller

I may have missed it; but, what truck year models spread are the right PowerStroke intercoolers ??

Thanks.

Ace

Mine was supposed to be a 2000, but got it from a guy off eBay, so can't be too sure. Late 90's to whatever year Ford dropped the 7.3, would be my guess.

DLittle

1999 to 2002 early 2003

I put a 1999 in my truck.

BearKiller

What kind of dollars are good used ones trading for??

What about new aftermarket/O.E.M. replacements; are they available and what do they cost??

Thanks.

Ggg

Aftermarket PSD intercoolers run about $1200 on up.
I don't know of any after market stock replacement PSD intercoolers.
Used prices vary a lot from a few hundred on up.
Only the Superdutyies had intercoolers from the factory, like was said 99-early 03. The 6.0 also has an intercooler but it is a different configuration and I don't know if it will work out as well in a Dodge.

Ace

I found a new TT (aftermarket type) on eBay for $300. Now I know why the guy wouldn't tell me how much he paid for it.

wannadiesel

I paid $120 for mine.

rbrettctd

What is the inside measurement of the tubes on one? Ive got to have enough clearance to get around my non crossflow radiator when I get there.

DLittle

I just put a tape on mine and it looks to be about 32in from inside to inside. I might be off about a 1/4in it's kind of hard to get a tape in there.

rbrettctd

Hey I think that might work...Ill have to check my radiator again. Tahnks.

G1625S

My '06 Dodge unit slipped by the factory non-ic radiator with no problem which leads me to think they're all pretty close. I'll try and put a tape on it tomorrow.

kiszka6911

I thought I would add my experience in installing the PS intercooler. My goals were to make this a bolt in process installed with only hand tools I also didn't want to modify the front grill in any visual way.

First off it will fit and clear the front grills. I learned a bits and peices from both of the previous threads.

All of the lower factory mounts and the center support must be removed. Secondly, you will need to clearance the core support so that the big intercooler pipes can go through. I used a saws-all and 4" angle grinder for this.





Next I learned from others that the intercooler had to be tipped forward at the top becasue the grill had more room. So after test fitting a few times and the tube angles getting funky I had the cooler upside down sitting next to the truck and I noticed that the tubes were parallel to the ground and the top was leaning forward.



I first tried to use the factory mount brackets but they put the cooler way to high and they mounted the cooler to far forward and interfered with the grill so the were cut off and blended smooth.

I then made up some flat stock and started playing with dimensions, first I got the AC condenser mounted. I also covered most of the sheet metal surfaces with a self adhesive rubber.



Once the ac unit was installed I then started work on the upper intercooler mount. it turned out to be a another peice of flat stock just high enough to clear ther condensers bolt head.



With this in I then could locate the lower mount. I used some 1 1/2" x 3/16" angle aluminum which will be TIG welded to the intercooler. A local welding shop is ding this for $30. Also not shown is the 1" PCV valve grommets which provide and lower soft mount. I used a 1" knock out tool at work to put thes holes in.



So there it is, finished picture to come after welding!

schamran

I think that your loss of boost could just be the air cooling that much more. When the air is cooled, it becomes more dense. I [I]think[I] your boost will be lower if your air is colder. Either way, you are doing more for performance than hot boost.

wannadiesel

Correct. It's typical to "lose" 3-5 psi due to the cooler temps.

That's why I have my wastegate boost line plumbed into the cold side of the intercooler. If you plumb it straight off the compressor, your boost pressure varies depending on ambient temp and road speed.

Alwaysworking

wouldn't that make the turbo have more boost on the hot side of the intercooler?
i plumed mine into the elbow off the turbo to limit the turbo to 35 psi. my thought was to keep the turbo running at 35psi vs running 40+ on the hot side of the i/c and only reading 35psi after the intercooler.