6.0 Intercooler in a 7.3? - Diesel Forum

Notch1320 · 03-20-2005, 10:56 AM

I just purchased a 6.0 intercooler at a swap meet. it is a bit bigger that the one on my 2002 7.3. Everything looks like it should just swap in without any issues. Would this benefit me at all? What kind of gains should I expect from doing this? I got an awsome deal I think, and a bigger intercooler can always help I would think. Not sure on which tubes to run though. The 6.0 tubes, well... one of them is compressed down at one point from the factory... I was going to look at my 7.3 ones to see if they were the same, and maybe look into either making a new one, or doing something to help in that area. Any suggestions? The only mods I currently have are a FTVB, drop in K&N, and MBRP 4" exhaust.

Thanks for your help!

McQueen · 03-20-2005, 11:28 AM

check out the archives i have seen this about a month ago

Moremph · 03-20-2005, 12:03 PM

thier was several posts in the archive on this exact swap

if memory serves me the 6.0 cooler is 33% bigger do not quote me on that, and will work i beleve sme minor fabrication is required like maybe new tubes

Travis

Josh F250 · 03-20-2005, 07:07 PM

I did it but used a Banks 6.0 IC. There was another guy on here who did it with the Ford version. Everyone I have read about doing the swap (including my self) had good results as far as EGT reduction. The swap is easy. The only thing that doesn't fit perfect are the pipes. What you have to do is cut your stock pipes shorter and make adapters to fit from your pipes to the new IC. I did it with Banks boot kits and exhaust adapters but the Banks IC has 3.5" outlets. Like others said, search for this and you will find detailed instuctions and results.

deeretrac · 03-20-2005, 08:18 PM

let me know if you want to get rid of the 7.3 intercooler CHEAP. Rob

Josh F250 · 03-20-2005, 08:37 PM

I have my 7.3 IC sitting in the corner of the shop, and I don't need it. Send me a PM if you're interested.

WFTREE · 03-21-2005, 10:59 AM

Below is the write up I did on the install any questions let me know. I have run 35 psi of boost from a long time with no problems.

WFTREE

With the EXPERT help of the guys from the Western New York Powerstroke Club, Thanks Gar, Jim, Jeff and Kory, I just finished the 6.0 intercooler.

The new intercooler is 31% bigger.

Original 30x18x2
6.0 30x21x2.25

It was easier than I thought, much of the time was on the fly engineering. I have not fired it up yet so I have a few concerns I will address.

INSTALLATION

Either drain radiator or drain enough to remove upper radiator hose
Remove over flow tank on top of the radiator
remove all radiator and AC condensor mounts but do not remove either
Remove upper radiator hose.
Remove bolts holding fan shroud
I have a stick so you might have to move the tranny cooler on an auto??

Remove 2 bolts holding Intercooler and hoses connecting to pipes

Tilt back the radiator as far as possible and pull the intercooler out. This will take some manuevering to get it clear of the AC lines(removing the condensor mounts allows moving of the lines) but it will come out. Better to have 2 people one at each end.

The new intercooler is 1/4 inch thicker so you will have to get the fan shroud in just the right spot and the radiator a little farther back to get the new one in place. again 2 people for this. Bolts right up to the original mounts.

NOW THE FUN PART

The intercooler tubes do not fit!

This took some time but our fearless leader Gar Hanson figured it out.

The inlet is smaller on the new intercooler, same size 3" as the intercooler tubes. The outlet is the same size as the original.

The inlet and outlet are also an inch shorter so we needed to fill this gap and figure out the size problem.

The solution was simple. you need 2 napa intercooler hoses Part number 1701 and 1740 and 2 extra clamps

Cut off 2.5 inches of the oultet pipe near the intercooler, passenger side of the truck, save this short piece. attactch the 1701 hose on the shortened intercooler pipe, attatch the 2.5 inch piece you cut off to connect the new hose from NAPA to the stock blue hose. This blue hose fits on the new intercooler. you use the new NAPA hose to add 1/2 to 1 inch of length. Cutting the pipe and reconnecting it with a 1/2 inch or so gap gives you the extra lenght you need.

On the other side the NAPA hose 1740 adds the extra length needed.

Thighten it all up! put the other parts back in place!

DONE

I figure about a 4 hour job all together if you eliminate the trip to NAPA and the on the fly engineering time

I have not fired it up, need to do coolant flush and fill but not today.

Kory and Gar took a lot of pictures and they will be posted at www.WNYPA.ORG soon

Notch1320 · 03-21-2005, 07:25 PM

Thanks for the details! I will be looking forward to checking out those pics as soon as you get them up. I haven't had a chance to really take a good look at all this, I just bought the intercooler on a thought... and a good deal. I was looking at maybe cutting the pipes and adding where I needed length, and even chaning the 7.3 ends out for the 6.0 ones since they came with the cooler. I would also like to fix the smashed pipe since I don't have the dual alternator set up, and maybe even have the pipes powdercoated, or sent for a Jet- Hot style coating just to make it look good? Let me know how it runs after you get it going... I am curious as to if you will notice any changes, or how the temps will change.

Thanks again...

WFTREE · 03-22-2005, 07:09 AM

I copied that from my post when I first installed it this winter. Since then I have several thousand miles (most miles towing 14,000lbs)and no problems, my boost is up to 35 and all is holding very well. EGT down about 100 degrees or so. I am running a new TS chip so it is hard to get an exact comparison.

WFTREE