Thanks for the poker game NYB .
Googs. Dude. I should have known better than to brag about my 8 inches, cause there is always another man who's got bigger. Even then, 10" maybe. But 12"???? Like they say, look out for the thunda down unda.
Thank you for the bigger pictures also. Your set up is mind blowing. Looks like all custom welded heat exchangers?
Is that the Ford OEM Transfer Case shield (FOTZ- 7E063-A) you used to mount and protect the Oil to Water cooler? Do you have a transfer case also, or do you have twin transfer case shields mounted in series, one protecting your transfer case and one protecting and holding the cooler?
Heck yes I'm PM'ing you for more pictures. I want to fully appreciate all the work that you did putting that all together. There is no question you won this hand of poker, but I'm going to lay all my cards out on the table to the lesser hand I had to fold with my pics below, since you so kindly obliged my request for larger pics.
The difference between the 7.3L auto trans cooler, and the V10 auto trans cooler. Photo taken in year 2000, long before this became a "mod" popularized on the forums. Yes, even before Brian at BTS did it. And long before the 6.0L coolers came out. But I still lost this hand. Oil to Water is definitely a more efficient way to remove heat, and while I did add the OEM OTW cooler (by installing a new radiator) with this upgrade, the total surface area of the OEM OTW in tank cooler is much smaller than the custom OTW cooler shown by Googs in his pics above this post.
Twin 8" PermaCool electric fans (specific parts utilized in upper left hand pic) being assembled on their own tubular support structure (rather than ziptied to the heat exchanger), with baffles and shroud constructed from sheet aluminum and durable rubber cut from mudflaps (specific parts utilized in upper right hand pic).
Installation close ups of the twin electric fans inside the rad support. In addition to a solid baffle over the top of the OTA trans cooler and fans (see middle column of pics, top and bottom), there is a "flow through" screen strategically positioned underneath the trans cooler bridging the gap between the cooler and the cross rail of the rad support, on either side of the power steering cooler (removed and not shown in these pics, but you know where it goes in the center), intended to provide at least as much resistance to air flow as the stacked plates of the heat exchanger fields of both the power steering cooler and the transmission cooler.
(See the middle row, center pic for the fans as mounted without the screen air diffuser, then see the adjacent left hand column middle pic for the diffusers as installed. The diffusers add resistance, but not entire blockage, to bypass air flow through the gap under the OTA transmission cooler).
The diffuser screen, made up of two layers of hard wire cloth (attic soffit vent screens from the hardware store) sandwiching a finer solar screen cloth, (source material shown in the upper left hand pic) is installed to discourage air from bypassing either the OTA trans or power steering cooler.
Cooling air pulled through by the engine fan or the electric fans, or both. At the same time it can be pushed through by frontal air pressure from moving forward, especially as directed by the lower twin scoops (shown in a separate pic at the end of this post). No matter what the source of the air is, the flow of the air AROUND the coolers is metered to a resistance greater than or equal to through the coolers, so that air is encouraged to flow through the coolers rather than anywhere else.
In this single photo above (single because it is recently taken, some 13 or 14 years after installation, whereas the other grouped photos posted above are rephotographed from old film prints layed out in a matrix), the solid aluminum top baffle is shown as riveted to the aluminum support tube that holds the fans in place close coupled to the transmission cooler.
That solid top surface is intended to do a couple of things...
1. The top aluminum shroud maintains a totally independent cooling air passage to the intercooler (seen in the photo) above the baffle, such that no heat rejected from the transmission cooler is introduced to the cooling air of the charge air cooler. I wanted maximum temperature drop for the brief amount of time that turbo charged air gets to visit the interooler, for the most air density derivable in the journey through the CAC ducts.
2. The top baffle covering the trans cooler to electric fan gap keeps the twin electric puller fans from drawing in air from anywhere else other than through the transmission cooler's heat exchanger field.
Finally, I added stealth wide mouth air scoops, necking inside through a narrower venturi, then expanding to a flow directed disbursement that captures some of the air flowing under the truck and channels it through the transmission cooler via ducting hidden within the bumper.
A secondary air dam captures the air that would otherwise create fuel robbing turbulence under the truck, and redirects that air into the transmission cooling scoops...
This is a 2000 truck, and from 1998 through mid 2001, the bumper and valance panel were solid as you see here. At some point in mid 2001, Ford cut out holes in the center of the bumper trim valance panel and chin spoiler to direct more cooling air to the lower half of the heat exchangers, and they did this not only in the Super Duty, but in the E Series vans as well. Perhaps they finally got the "right person" on that job.
Nevertheless, even if I updated to the later style bumper, air dam, and valance panel trim, my hidden front winch and front receiver hitch (that doubled as a "Blocker Beam" before Ford came out with them) ... would have prevented Ford's after the fact cooling air flow remediation through their 2002 model year bumper trim. Hence these hidden scoops.
There are actually a total of nine very stealthy hidden scoops in the front of my truck, that are screened, well drained, ducted, and directed towards either cooling needs or inlet air needs. Snow and water mitigation measures are incorporated into all of them, but testing of their efficacy in that regard is severely limited where I live, so in spite of my best efforts to consider the worst case scenario, I'm not suggesting that anything that I have done here would pass the same vetting process that an OEM would require.
But lets face it, almost anything is better than what Ford originally "vetted" during 1996-1997 when the 99 up Super Duty diesel was nearing release. Even this weekend hack achieved MUCH MUCH MUCH better and MEASURABLE transmission cooling with the foregoing measures.