Hey there, has anyone modified a 2nd gen intercooler to fit a 1st gen intercooled truck? I know they fit nicely in a non-intercooled truck because of the narrower radiator, but what about an intercooled truck. Seems to me the 2nd gen intercooler was narrower, and the inlet and outlet pipes would get into the radiator. Anyone ever widen one? A PS intercooler is too much work so that is out of the question. I need something with little to no modification to the truck. A plug and play kind of deal.

 

The 2ndgen IC is wide. If you cut the 1stgen IC rad support to fit, you cut through the stiffeners/uprights that dodge added to accommodate the stock IC. You would be further ahead to snag a gas rad support to modify for the 2ndgen intercooler.

​​Re-read some threads on the PSD intercooler swap. It is the easier route with the IC support.

Found one writeup....
https://www.dieselbombers.com/dodge-diesel-tech-articles/32132-one-way-install-powerstroke-intercooler.html
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