minipete

hey guyz, quick question. would an intercooler from a 99-02 stroker work in our trucks? if so what kinda fabs would it take to make it work?

Dan

kiszka6911

Do a search on powerstroke intercooler. There are several threads where people have done it, I have been working on it.

So far everyone has taken slightly different approaches. There are some great write ups with pictures. Look at them all!!!! this will give you a great idea on whats involved. My goal is to make it fit as a bolt in. Installed without torches or a plasma cutter. So far I have used a 5" angle grinder, and a saws-all, and a cordless drill.

wannadiesel

It's working on mine.

Ace did a better install on his truck, it's in the sticky.

dpuckett

Kizka6911- I did the same thing on mine. Plasma and torch spray too many sparks into the engine bay onto 15year old wiring. I used a grinder and cutting wheels on the grinder.

DP

kiszka6911

Just thought I would give you and update.

Cooler tubes are in, along with the powerstroke intercooler (PSIC). Everthing seem to fit near perfectly. I went a different route and installed the PSIC upside down from the Ford factory install which allowed the top to tip forward and kept the output tubes at good angles. I had to have new brackets welded on but this was a small expense $25

Everthing is behind the grill with only minor valence trimming, all orginal screws are used and no trimming any gril panels.

I will have to shorten the hood latch or bend it at a greater angle. I also tried to turn it 90 degrees with no luck.

I got hoses that are used when a 6.0 powerstroke intercooler is installed in an older truck. This made the swap very easy as they are 8" long. Which made the cooler tube lenghts a non issue.

They came from here.
http://dieselpowerproducts.com/shopp...php?id=97&=SID

Also needed was a transition hose from the turbo output 2.5" to 3" to the cooler tubes and all new badn clamps.

I am also going to get a 3" hump hose because there is a small mis-alignment with the driver side tubes, its small but needed.

Also needed to have on hand are gaskets for the grid heaters to the intake and grid heaters to the cooler tubes.

I also forgot to check the flatness of the cooler tube mount, I have a small whistle which I think is coming from a reused gasket at 30+ PSI. Final pictures coming soon.

Mattster

Sounds cool. I'm bidding on a 7.3 intercooler to put in mine since i have no intercooler.