Replaced my 05 plastic sided intercooler with a stock 06 metal sided intercooler and noticed a difference other than the plastic vs metal sides. The stock plastic sided 05 intercooler is only 2" thick. The 06 intercooler is 2 3/8 " thick. So here's my question. Are the 06's intercoolers thicker than the metal sided 03, 04 and late 05's? Or are all of the metal sided 03-06 intercoolers 2 3/8" thick? If this is the case, that is another reason to replace the early 05 plastic ones. They can't be as effiecent as the thicker ones. If the 06's are in fact thicker than the 03-05's, does this mean they are engineered to meet the demands of the new 07+ 6.7 Cummins?

 

03-04 had a smaller intercooler then the 04 1/2. 05 they went to the plastic, but 1/2 way threw the year they went back to the metal sided ones like the 04 1/2.

I knew 3 guys with the 05 plastic intercooler every one blew and DC replaced them with the metal ones. Not sure if the 06 is different then the 05 metal sided one's.

 

Oops! Should be in Engine and Drivetrain forum. Mod please move.

 

I believe the late model 05 and 06 are the same width. I have to take a look at the 04 to see the width on theirs.