The 7.3-liter Power Stroke is a legendary engine, but its stock intercooler has always been a weak point, especially for truck owners who tow heavy loads. The 6.0-liter intercooler swap is a classic, proven upgrade, and Cameron Lewis of KC Turbos just dropped a detailed 6.0-liter intercooler installation guide on how to get it done.

The Teardown And A Dose Of Realism

The video starts with the teardown of a L99-03, which involves removing the top cowl and the entire upper radiator support. Cameron provides a refreshingly honest look at the toughest part of the job: prying the old, often-stuck support bar off the front of the truck. “Be a little careful so you don’t bend the ever-loving crap out of your radiator sport,” he warned, adding, “This thing is going to take some force to get off.” It’s a dose of realism that any home mechanic who has fought with old, crusty parts can appreciate.

Why A 6.0-liter Intercooler Installation Is A “No-Brainer”

With the old intercooler out, Cameron laid out exactly why this swap is considered one of the best no-brainer upgrades for a 7.3-liter tow rig. He compared the stock 2-inch thick unit to the much larger 3-inch thick, bar-and-plate 6.0-liter cooler. The size difference, along with better-flowing cast end tanks, results in a massive cooling improvement. As Cameron pointed out, “You can see it’s like a 35-percent increase in volume just by switching to this intercooler.” That huge increase in cooling capacity is critical for keeping Exhaust Gas Temperatures (EGTs) down and maintaining power on long grades.

The Assembly And A Pro-Tip

The installation process involves dropping in the new intercooler and wrestling with new, high-quality boots, which Cameron admits can be a pain. However, he shared the single most important tip for the entire 6.0-liter intercooler installation to prevent fighting with alignment issues. “Save yourself some headache,” he advised. “Locate this intercooler first with these mounting bolts [on the support bar], and then tighten down your boots.” This simple sequence ensures that everything lines up perfectly without putting any tension on the intercooler pipes.

More Than Just Dropping In A Part

The KC Turbos guide proves that while this is a popular swap, doing it right is more than just dropping in a bigger part. It’s a process that requires careful disassembly, attention to detail, and a few key shop tricks to get a clean, professional result. By showing the entire process, warts and all, the team provided a perfect roadmap for any 7.3-liter owner looking to complete a 6.0-liter intercooler installation and add a huge boost in cooling performance and reliability to their truck.