Charge air cooler upgrade?

[Shadrach]

I have read lots on here about upgrading the cac. I would like to hear from those who have done this. I don't mind going the trouble of putting in a 2nd gen cac, but is it really necessary? Also how much power have you put through the stock 1st gen cooler? I won't be running more than 300hp and will be pulling a 10k trailer at times. One local speed shop says the stock one is good for 300 ponies and a remanufacturer of aftermarket coolers states that they are marginal at best?? My friend has a 93 with a 97 engine and is over 300hp. He took the stock cooler and had the ends changed to 3" and then ran 3" tubing for the rest of the system. Your thought and comments please! Shadrach

 

[Makaio]

Shadrach,



A larger intercooler with 3" tubing will keep your EGT's down. Another option is a '99-'02 (I think those are the years) Powerstroke intercooler with the larger tubing. A lot of the guys have done this conversion with minimal modifications and fitment is pretty good. It moves a good volume of air.



Aloha,

Matt

 

[Headshot zod]

Make sure that when you get the powerstroke IC get an earlier one that is aluminum the later models are plastic.

 

[dpuckett]

Well worth it, IMO. I put in a 96 intercooler over the weekend, and dropped EGT about 300deg across the board. Boost is about the same, but with the EGT being significantly lower, I'd say it is flowing more air. That is good for everything involved, from the boots to the turbo, to the head gasket.



I dont know if it is NEEDED for 300hp, but if you come across a good used one, it cant hurt.



Daniel

 

[Shadrach]

Thanks guys Does anyone have the original Ferd p/n from an aluminum cac? Daniel Did you mount it upside down? or normal? What problems did you encounter? I have a 97 cac from my parts truck although I would prefer a newer model so I could have 3" connections. Shadrach

 

[dpuckett]

I installed it "normal", and I would have made the lower brackets closer to the core support, but other than that, it was just cut, weld (core support), and install. (I'll have to move the lower brackets anyway, just to get the A/C condensor back in there. ) The air tubes need to be cut about 1-2" to make a seamless install- my boots hang over the rings in the metal tubes. I have it in there for now, and will modify as needed as I go along.



9deg EGT per MPH is nice on a 110deg day.



DP