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2007 – Ford Powerstroke 6.4L Upgrade Front Intercooler

May 29th, 2009 · No Comments

Removal
1. On the upper boost tube, loosen the hose clamp on the intercooler side using a 11mm socket and pull the silicone tube away from the intercooler.
2. Loosen both hose clamps for the bottom boost tube using a 11mm socket and remove the factory silicone hose from the boost tube and intercooler.
3. Using a 10mm socket, remove the two bolts that secure the factory oil cooler to the intercooler and the vehicle’s frame. One of the bolts is located on the top of the cooler, securing it to the factory intercooler, and the second is on the bottom of the oil cooler, securing it to the frame of the vehicle.
4. Gently lift the oil cooler up, out of the slot on the intercooler and set it on the side carefully.
5. Remove the two bolts that secure the top of the factory intercooler to the radiator support using a 10mm socket, and remove both rubber grommets from the factory intercooler.
6. Remove the factory intercooler from the vehicle.
7. With two hands, one on each side (bracket), carefully push the oil cooler behind the factory intercooler towards the condenser, so the gap between the condenser and the cooler is no more than 0.595″.
8. Install the two new supplied “Z” brackets (P/N 21788) into the vehicle by inserting the dowels into the factory rubber grommet on the bottom cross member.

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