Inner Cooler Install on A 96 - Ford Powerstroke Diesel Forum
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post #1 of 20 Old 01-17-2012, 07:42 PM Thread Starter
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Inner Cooler Install on A 96

Finally got around to putting the inner cooler in on my 96 F-350. Have had the parts for almost a year. Got the 6.0l cooler for free, the E99 spyder for $100, the pipes for $200, 2ft piece of silicone hose for $50, and 1 factory hose for free.
The disassembled front end


The pipes and hose


The cooler


Core support marked for the inner cooler


Brackets made for AC condenser



Spyder Installed


Support Straightened


Brackets paint for final install



Cutting the holes in the core support





Test fitting the cooler








Brackets welded and painted



Had to have one pipe fixed.


Final install of the inner cooler











Still have to install a couple of clamps, Mount the trans cooler and put the front end back together. More pics to come

96 F-350 PSD 4X4 Crew Cab Long Bed, Superchips programmer, exhaust, HPOP crossover hose, trans, pyro, boost gauges
76 F-250 460 4x4 long bed
66 F-100 302 4x2 stepside
07 F-150 5.4 Crew cab 4x4 w/ 6.5ft bed
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post #2 of 20 Old 01-17-2012, 09:08 PM
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looks great, very professional looking, looks like when i started my install, winch wouldnt let me keep it tho

-Kris-
2000 excursion V10 2wd 230k
2000 Excursion 7.3 4x4 246k
1995 CCLB DRW 324K
2001 CCLB DRW 319K
Dp tuner infinity, exhaust, intake, chipped, tricked, and wrecked
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Quote:
Originally Posted by marine5811
The stock downpipe in an OBS is flat because I'm a ginger.
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Well at least you caught the loose bolts before they cause any damage. Nothing worse than a sloppy hole
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post #3 of 20 Old 01-17-2012, 09:38 PM
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nice job man, i have a inner cooler as well but was wondering about a trans cooler as you said you were mounting one, where at cause i read on a different thread that it was difficult to mount because of lack of space, details on how you plan to do this would be much appreciated.

-Brandon-
1996 F 350 7.3L CCLB
6637 Intake; Banks: Intercooler, Up Pipes, Turbo; PHP Phoenix
4" down-pipe, cat delete,muffler delete, 4" turbo back exhaust
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post #4 of 20 Old 01-17-2012, 10:10 PM Thread Starter
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Figure the trans cooler is gonna go on the headlight support that the grill bolts to.

96 F-350 PSD 4X4 Crew Cab Long Bed, Superchips programmer, exhaust, HPOP crossover hose, trans, pyro, boost gauges
76 F-250 460 4x4 long bed
66 F-100 302 4x2 stepside
07 F-150 5.4 Crew cab 4x4 w/ 6.5ft bed
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post #5 of 20 Old 01-18-2012, 07:04 AM
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Trans coolers fit fine, when you go to a bigger trans cooler, you just cut the center out of the header panel


Elmo/Shane

96 F350 4x4
Everything.
And its expensive.

476,000 Miles

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post #6 of 20 Old 01-18-2012, 02:54 PM
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could go to a tru-cool maxx and mount it in the bumper.. they are good coolers and have a small but thick design

FRANK THE TANK
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DIY INTAKE - HYDRA CHIP - MARTY'S E-FUEL - 250/200s
05 AXLE SWAP 3.73 - 2.5" PURE PERF. LIFT COILS - FOX SHOCKS
BTS TRANS - TYMAR DOWN PIPE - 4" EXHAUST
Waiting To Be Installed... gtx4294r, studs, springs, HPOP?

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post #7 of 20 Old 01-20-2012, 07:05 PM
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i want to do this but like 351fifty i have a winch and bumper. Are there any alternatives? Smaller IC?

1997 F350 SRW RCLB, 4.10s, RSK 4" on 37" Toyo M/T's, Tony Wildman 6 Pos., 3 Pillar Gauge Pod with Trans Temp, Boost and EGT's, BTS Valve Body, AFE Intake, 3" DP to 4" to Dual 6" Stacks, Custom Front Bumper, 12k Winch

Project 5 Speed soon to Come
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post #8 of 20 Old 01-24-2012, 08:12 PM Thread Starter
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Finally got around to finishing it up. Got the headlight support on


Grill is installed


Had to weld brackets to the bumper mounts for the trans cooler


Got the trans cooler installed


Bumper is on


Got take the truck to a buddies and gonna have build a splash shield for the bumper to protect the trans cooler lines and bottom part of the inner cooler

96 F-350 PSD 4X4 Crew Cab Long Bed, Superchips programmer, exhaust, HPOP crossover hose, trans, pyro, boost gauges
76 F-250 460 4x4 long bed
66 F-100 302 4x2 stepside
07 F-150 5.4 Crew cab 4x4 w/ 6.5ft bed

Last edited by Crusader Kid; 01-24-2012 at 08:49 PM.
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post #9 of 20 Old 01-24-2012, 08:39 PM
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looks awesome, i like the trans mount location, just makes me want a welder in a bad way, i may eve build my own bumper for the winch at that point lol

-Kris-
2000 excursion V10 2wd 230k
2000 Excursion 7.3 4x4 246k
1995 CCLB DRW 324K
2001 CCLB DRW 319K
Dp tuner infinity, exhaust, intake, chipped, tricked, and wrecked
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Quote:
Originally Posted by marine5811
The stock downpipe in an OBS is flat because I'm a ginger.
Quote:
Originally Posted by alberta 7.3
Finding a decent woman is like shopping for a used truck. You spend most of your time picking through the money pits, wrecks, and basket cases until you find one that you can tolerate
Quote:
Originally Posted by JJFLASH
Well at least you caught the loose bolts before they cause any damage. Nothing worse than a sloppy hole
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post #10 of 20 Old 01-25-2012, 04:02 PM
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welders arent that expensive Kris.... saw a 110v lincon MIG welder at home depot with the gas hook up for like $550. small stick welders are like $200 or less

intercooler looks great... i like how you took the time to mount it properly, was there any way to mount the intercooler higher to allow more air thru the grill to get to it? or does that make the pipes come thru to high?

FRANK THE TANK
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DIY INTAKE - HYDRA CHIP - MARTY'S E-FUEL - 250/200s
05 AXLE SWAP 3.73 - 2.5" PURE PERF. LIFT COILS - FOX SHOCKS
BTS TRANS - TYMAR DOWN PIPE - 4" EXHAUST
Waiting To Be Installed... gtx4294r, studs, springs, HPOP?

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Quote:
Originally Posted by STROKED_NY_023 View Post
You are so smart Frank, I dont care what Terry says.
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