Intercooler Install - Diesel Forum - TheDieselStop.com
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Upgrades and Aftermarket - 6.0L Engine Upgrading or adding OEM or aftermarket equipment to your 2003-Up Super Duty or Excursion with 6.0L Power Stroke diesel engine. Please confine discussion of topics in this forum to those items that are specific to the 6.0L Power Stroke engine.

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Old 01-31-2008, 10:51 PM   #1 (permalink)
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Intercooler Install

I just wanted to ask you guys if you had any tips or things to make an intercooler installation any easier..I know its not hard but sometimes there are a few tricks you wish you knew before..I am helping a buddy put a banks intercooler on saturday on a 06 6.0...Thanks for the input!!
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Old 02-01-2008, 07:52 AM   #2 (permalink)
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Don't rush, have some pry bars handy, and enjoy working on your truck.

I did one on my '04 and it's not difficult at all, pretty basic mechanic stuff.
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Old 02-01-2008, 12:02 PM   #3 (permalink)
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Take your time getting the fan guard off. Pry to hard with a small screw driver and you will bust the bars in the slots in the guard itself. I have installed 2 of them not really that hard at all.
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Old 02-01-2008, 12:12 PM   #4 (permalink)
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I did one last year on my 03 6.0. Took half the day but I took my time. Have patience and like Heavy Assault said "have some prybars handy" other than that have fun
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Old 02-01-2008, 08:54 PM   #5 (permalink)
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I just installed a Banks Intercooler on my 05' 6.0L. It took about 3 to 3.5 hours from start to start up. When you need to take the crossmember out, start with a really big flathead to just lift it alittle. Then you can go and use the prybar, just becareful and don't bend anything. And don't forget when you take the hood latch off, go out the latch with a sharpie marker so when reinstalling it, it'll be in the same spot. And when installing the hot side tube, put the connecting tube on the turbo first and squeeze it in, its a tight fit since the alternator and oil stick is right there. Hopefully some of these help you out, enjoy and have fun man.
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