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My brother has a 6.0 E-series. They did things like move both batteries to the frame and install a different radiator to make room for the intercooler. An awful lot of packaging went into fitting the 6.0 in the vans. I suspect that a good mechanic with a full complement of tools would be able to see the engine block or a cylinder head of a 6.0L within 15 minutes or so.
My personal feeling is if someone chose to modify the intake resonator, relocate the fuel filter assembly, relocate the battery, relocate the air filters on a 7.3L and switch to a 6.0L radiator, the 2004+ intercooler would work. If I had the ambition to undertake such a project, however, I would be looking at an air-to-water intercooler. More expensive, but a lot cleaner installation.
A few people on this forum have initiated intercooler projects on their 7.3L E-series, but I've never seen a completed one yet. It obviously isn't an easy project.
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2003 E-350 14-passenger, 3.73 axle, Quadvan 4x4, AIC, TransferFlow 46 gallon tank, DP tuner, DieHard Platinums, PIAA driving lights, 17" Hakkapelliitas snow tires, 18" Continental ContiTrac summer tires, front receiver hitch
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