There are literally more threads in this section with write-ups and info about installing retrofit intercoolers then you could read,
but for the quick points, you need the early 99 y-pipe, the late 99 and up does not fit on the obs, (the early 99 SD had the small turbo), the pipes will usually need some slight modification depending on how you mount the core and where you do the cutouts in the cab,
this is if you are going to use all the oem SD parts(which I assume you want to do since you mention getting everything from the SD), if your using aftermarket pipes or y-pipe it would be a little easier, but cost you more.
After researching this- I think I would rather buy a used unit- probably a 6.0- and then get a kit for piping, etc. as I do not have skills or access to equipment to fab pipes. Does anyone know where I can currently get a kit that includes everything to use a used 6.0 core or possibly a 7.3. I saw talk of a banks kit and maybe others but I can't find any direct links to these kits.
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1994 F250, Tymar, Tuff country 2" lift
Ive done it to two trucks. the hardest part is making a bracket for the intercooler. everything else should bolt up. the thing is you put the pipes off the earlier truck and put them on opposite sides and upside down, they fit perfectly, plus you need the Y at the turbo.
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1995 F-250 7.3, diamond eye 3.5 in down pipe and 4 in. straight pipe, ZF 5 speed, 4.10, TS 6 Position, Tymar Intake.
There seems to be conflicting info on this subject- some people say no problem to use 99 pipes and others say there is cutting, welding, and tube bending involved. If it was just fabbing brackets for the cooler I could probably handle that? Can anyone shed any light on why some people had to cut and some did not? Also can I use the 6.0 unit or would it be way easier to use a 7.3. I know I need an early 99 spider.
Teamheeler- what about the method you suggest? how much cutting to rad support, etc?
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1994 F250, Tymar, Tuff country 2" lift
The main difference between the installs is the placement of the core. Some have been able to use the pipes without modification depending on how they did the mounts.
You basically need to cut a 3.5" hole on each side of the radiator.
I don't think there is any tube bending though, I think most end up needing a little more length.
The only thing about the core is you have to take the radiator off, weld some brackets, fabricated by you to fit the core, install the radiator, and flip the tubing opposite sides and upside down.
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1995 F-250 7.3, diamond eye 3.5 in down pipe and 4 in. straight pipe, ZF 5 speed, 4.10, TS 6 Position, Tymar Intake.
6.0 cooler will not work. I have a 97 f250 about to install one.Its off a early 99 its suppose to work with min. cutting. Im looking for some more help too. gtsmotorsports was good but I didnt save the pics.
Plenty of folks have used the IC off the 6.0 trucks successfully. Anyway, regarding the 99 IC retrofit, I have a Word document with all the text and pics from the old GTS webpage. PM me your email address if you want a copy (it's about 1.2 - 1.3 Megabytes). Cheers!
I have the GTS "kit" installed, with a 2001 Intercooler and it works perfectly. Not sure if Geoff is in the business of building kits any more, but those he built make for a perfect fit!
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IDM mod
TYMAR intake
Amsoil dual by-pass
Precision Ind triple disk Torque Convertor & Pro build tranny
Transgo Tugger shift kit
Ford AIC & full gauges
Mini-Me/SWAMP 250cc Hybrid 530 injectors
17° HPOP
5" custom exhaust
Superduty Intercooler & GTS pipe kit
CCV mod
TS 4 position Flip Chip
6.0 cooler will not work. I have a 97 f250 about to install one.Its off a early 99 its suppose to work with min. cutting. Im looking for some more help too. gtsmotorsports was good but I didnt save the pics.
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2 1995 C350 Centurion conversions. Both are PSD, E4OD, 4x4, and 4.10
One is heavily modded,Gear vender,Rear disk brakes,53 gallon fuel tank,velvet rides,Stage 1,6.0 intercooler,TW 4 spot chip,Big Air,ceramic coated down pipe to 5"over the axle,exhaust brake,AIC,IDM mod.
The other is waiting to see how the first one turns out. FourDoorBronco.com
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