Intercoolers

[BV]

Originally posted by britannic

Well, sadly I didn't realize that Ford changed their dimensions (or they may not have - need advice here please) for the 2003 PSD intecooler (18"x30"x2"), so the one I got isn't going to work with the stock radiator and core supports (unless I completely remove them) and change to a narrower radiator.



My truck was originally a 6. 2L diesel with the big radiator (40. 5"x21"x3. 5" overall). . I notice that the Dodge '99 intercooler is 46" x 15 1/2" x 2 1/4" with 3 1/2 inlet and outlets, so that may be more feasible.



If anyone has the dimensions of the earlier Ford PSD intercoolers and which years they were fitted, I would greatly appreciate it.

Can't help on the size but I do know that the 99's had aluminum tanks instead of plastic.



Check out this sight for dimensions: http://www.chargeaircoolers.com/catalog.htm

 

[britannic]

I got the 1999 DC intercooler today and was pleased to find that the inlet and outlet flatten to a rounded off rectangle where they join the end tanks. This increases the available gap between the inlet and outlet to 40. 5". Which makes it 1/4" too small at either end for the OEM Chevy diesel radiator, but I'm going to get a 4 core aluminum one that'll fit better in any case.



I'll mount it in front of where the A/C evaporator core would normally sit and cut 2 holes in the core support for the inlet and outlet.

 

[DKarvwnaris]

Originally posted by britannic

I got the 1999 DC intercooler today and was pleased to find that the inlet and outlet flatten to a rounded off rectangle where they join the end tanks. This increases the available gap between the inlet and outlet to 40. 5". Which makes it 1/4" too small at either end for the OEM Chevy diesel radiator, but I'm going to get a 4 core aluminum one that'll fit better in any case.

Britannic,

I have cut the inlet/outlets off of the dodge inner coolers before and tig welded them 180 degrees around to make more room for the innercooler lines. This works well to accomodate the Ford's as well as the GM core supports. It is not alot of work to do so and will give you at least 4" of extra full clearance between the cooler outlets.

 

[dcamilleri]

britannic,

like the last reply, simply cut off the intercooler inlets and swap from side to side. This will give you enough room to clear the radiator support without cutting the vertical structural members. The aluminum on the inlets is of good quality and is about 1/4" thick and welds great. Also the 6. 2 radiator can be made to fit by modifying the end tank(s) I used a radiator from a 97 dodge which allowed me to use stock lower radiator hose with a little trimming.

 

[britannic]

DKarvwnaris, dcamilleri: I think you're saying, cut the inlet off at the tank, rotate it 180*, weld it back in place and then do the same for the outlet?

 

[DKarvwnaris]

That's the idea. It is alot easier than trying to refab the structural parts of the core support. If you then lightly reform the front edges of the fender wells on the GM trucks, the cooler tubes will fit in with no problem at all.

 

[britannic]

Good news on my military K30: the core support pillars are 36. 5" on the outsides and the width between the intercooler inlet and outlet ODs is 38", so I won't have to do any cutting, welding or fender mods .