6.4 INTERCOOLER IN A 6.0 - Ford Powerstroke Diesel Forum
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Old 08-11-2012, 06:19 PM
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6.4 INTERCOOLER IN A 6.0

Ok everyone since my idea was derailing Adrian's thread on the MTW's Stage 3 Turbo I decided to start a new thread for everyone to voice opinions, ideas, and specs here.

My original thoughts were that due to the 6.4 using a compound setup that can flow almost double the psi of boost pressure than a 6.0 can in stock form than the 6.4 intercooler would be a good idea for a swap instead of having to go the high dollar route of a banks, spearco, or aem intercooler all of which will run you over $1200 to buy and install.

Now I know it would require a little fab work to make it happen and custom cac piping but I think this can be done and for a lot cheaper than an aftermarket route.

The 6.4 intercooler also has the cac inlet on the top and the cac outlet on the bottom forcing the air inside to use all of the cooling capacity of the cooler vs the 6.0 where the cac inlet is in the middle of the side and the cac outlet is directly opposite that of the inlet, thus not utilizing the full cooling capability of the cooler.

Now I don't know that this will be a better upgrade than say a banks intercooler kit but I strongly feel it would be a much better upgrade over stock. That and it would be much more cost effective over an aftermarket route as you can buy a brand new 6.4 intercooler from sunriseford.com one of our supporting vendors for less than $500.

Another thing that has me thinking this will work is that the 7.3 guys are currently swapping to a 6.0 intercooler because the cooler is bigger and can thus flow/cool more air than the stock 7.3 cooler can and is much more cost effective than going aftermarket.

Let me know any and all information to either uphold this theory or prove otherwise. Thanks guys.
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Old 08-11-2012, 06:24 PM
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Ok, so you beat me to the thread idea, Tuscany.

I'm searching for information on these intercoolers as we speak.
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Old 08-11-2012, 06:27 PM
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LOL I just figured since I derailed Adrian's thread with the idea I should make a new thread like you said to give him his back.
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Old 08-11-2012, 06:27 PM
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sorry wrong post
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Old 08-11-2012, 06:28 PM
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Are you really?? Post the link here for future reference please.

Being that your a ford tech what is the size difference, mounting difference, and cac inlet and outlet hurdles you had to overcome?
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Old 08-11-2012, 06:28 PM
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Got a link to that thread by chance, Jugernaut?
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Old 08-11-2012, 06:29 PM
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Didn't you do the 6.7L intercooler not the 6.4L or did I miss something??
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Old 08-11-2012, 06:30 PM
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Now that you said something Nate I remember that thread and yes it was a 6.7 intercooler. He also said something about a dry ice setup with it as well.
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Old 08-11-2012, 06:37 PM
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So basically, not what we're looking for.

Here's the 6.4L intercooler:


That is a lot of surface area to get crammed in the front end of the truck, without doing an '08-'10 face lift.

Here's the 6.7L intercooler:


A lot smaller, and easier to get into these trucks.

Initial images, as I continue my search. I think this may be more complicated than expected, but not impossible.

Take note how the '11 (realize image is aftermarket) seems to revert to the centerline design. I have a theory as to why the 6.4L's cross section isn't as big a benefit as some think. Allow me to work on my explanation.
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Old 08-11-2012, 06:46 PM
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Doesn't the 6.7 have a water to air intercooler?
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