I recently got a 7.3 psd intercooler, and im attempting to install it in my non intercooler truck. The intercooler is off a 7.3, but it has plastic end tanks. It seems a really tight fit, almost too narrow, and a little too tall. I know people have put ps ic's in intercooled first gens, and first gen intercoolers in non intercooled trucks, but has anyone had experience with my situation. Any sugestions would be apprecitated.

 

I think the 2nd gen IC is an easier install on a non-IC truck. There's a good writeup in the sticky.

 

Yeah, i've been looking at that write up as well as others. Its kind of too late to do a 2nd gen intercooler cause i have a couple hours into making this ps one fit, plus i got it cheap. I guess i'll just have to trim a bunch off the bottom valence to make it all fit. My truck is far from show quality, so i'm not too concerned.

 

The whole middle of mine is gone, join the club.

 

They fit.





You have to cut everything but it will go in there.








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I just got done puttin a 2nd gen cooler in mine and had to do some trimming on the lower filler panel

If you use a 2nd gen cooler you wont have to cut the radiator brackets or the bracing that the rad bolts to

 

hahaha, you ain't kiddin'. I don't think i'm going that extreme, but the bottom half is gone. I'll put some pictures up later. thanks for the help

 

keep it under 40 psi or the tanks will blow off the cooler.

 

I have a 91 non ic with A/C. Does the 91-93 grill give more room to fit an ic? Will a Powerstroke intercooler fit my truck or should I use a second gen also? Is there any difference between 12 and 24 valve ic's?

 

24V IC is like 1 inch taller.

 

I put ps ic with the aluminum ends on in mine. I had to cut part of the radiator down brace along the sides of the rad so it would fit. I didn't have to cut the valance I just bolted one side up and then bent it around the ic and bolted the other side up. I also trimmed the factory grill to fit. I don't think it looks to bad myself but I don't have any pics to share. I also removed the center brace that runs from the top to bottom on the core support and cut the bottom off of the latch so it wouldn't hit the ic.

 

define "under psi." I talked to a friend of mine who is big into the powerstrokes and he said he never heard of any problems with the plastic end tanks. I'm only running 35-40 psi, so i dont think it will be a problem.

 

sorry i guess my number lock wasn't on

keep it under 40 psi, the tanks blow around 40 to 45 psi.

 

WIll an intercooler off a98 F550 fit our applications? It's quite large and is all aluminum.

 

Bigger is better, but sometimes you just run out of room. I just got done stuffing a 7.3 intercooler in mine, and theres isn't a 1/4" to spare.