Today I show you how to upgrade from the stock intercooler to an aftermarket Dura-Lite charge air cooler. Dura-Lite's charge air coolers are built extremely well and come with an even better warranty. This style of intercooler is a reproduction of the 7.3L powerstroke intercooler and fit very well into our trucks. With some trimming and bracket fabrication they can be mounted in front of the a/c condenser and no trimming is required to the front grille or valence. Please see below for extensive parts list. I have reached out to Dura-Lite and they are looking into the feasibility of getting a production run done for us. Stay tuned for more info on that.

Cheers!

Tyler,
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Complete Parts List:
-Dura-Lite Charge Air Cooler, Intercooler part number US-FODAC-26E
-24v intake horn (98-02) Cummins (e-bay or marketplace)
-Cummins Intake horn bolts, short: 3919864, long: 3943682 (216 in lbs, 18ft lbs)
-Cummins intake horn gasket x 2 3969988 (above & below grid heater)
-Cummins turbo outlet elbow 3” and o ring part number 3918685
-1/8”NPT plugs: https://amzn.to/3BWN9G1
-3” aluminum straight pipe compressor to intercooler 2ft: http://www.siliconeintakes.com/alumin...
-3” aluminum 45 elbow 2ft intercooler to intake horn: http://www.siliconeintakes.com/alumin...
-8 x stainless spring loaded band clamps, vibrant 27830 x 6 and 27832 x 2 (intercooler inlet and outlet were a bit bigger) ,
-4 x intercooler boots, I recommend getting 4 x reinforced vibrant 11820 instead of 2 and 2 hump hose style. Hump hose style are 2 x hump hoses vibrant 27344 in case you want to go that route
-Lower charge air cooler brackets, bent up zinc coated steel brackets found at canadian tire and used 5/16 body bolts tapped into the lower core support
-Neoprene Rubber: https://amzn.to/3zWH3DY
-3M weatherstrip adhesive: https://amzn.to/3ffm474
-Rubber grommet spacers for 3/8" bolts found at Canadian Tire
-3/8" bolts, nuts, and washers (2 each) (1.5" for ac condenser and 2" for intercooler):
1.5" bolts: https://amzn.to/3lgFKLR
2" bolts: https://amzn.to/3xkyBwd
-Bead Roller Kit Princess Auto: https://www.princessauto.com/en/18-1-...
-air grinder cutoff tool: https://amzn.to/3ffH7Xv
-air grinder cutoff wheels: https://amzn.to/3ybxY9E

BUY THE ITEMS IN THIS VIDEO (AMAZON.COM):
Video Equipment:
GoPro7: https://amzn.to/2UdHtnk

GoPro Accessory Kit: https://amzn.to/3bl9wXy
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BUY THE ITEMS IN THIS VIDEO (AMAZON.CA):
Video Equipment:
GoPro7: https://amzn.to/2UdHtnk
GoPro Accessory Kit: https://amzn.to/3bl9wXy
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CONTACT ME:
E-Mail: [email protected]
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