The CSF 6028 is a heavy-duty, high-performance bar-and-plate charge air cooler (CAC) intercooler engineered specifically for 2003–2007 Ford F-250, F-350, F-450, and F-550 Super Duty trucks and 2003–2005 Ford Excursions equipped with the 6.0L Powerstroke diesel engine. Stepping up from standard tube-and-fin configurations, the 6028 utilizes an extreme-duty, high-density aluminum bar-and-plate core furnace-brazed to heavy-duty cast aluminum end tanks. Built with 100% TIG-welded, all-aluminum construction, this core delivers vastly superior thermal inertia, heat dissipation, and structural rigidity compared to OEM units. It easily handles sustained elevated boost pressures, extreme heat cycling, and heavy towing without ballooning, cracking, or suffering heat-soak performance fade.

Catastrophic end tank blowouts along factory crimp seams, cracked plastic end tanks, boost leaks past degraded tank O-ring seals, heat-soak power loss during long hill climbs, elevated exhaust gas temperatures (EGTs), sluggish throttle response, and lost manifold pressure under aggressive tuning are what this core cures. Factory 6.0L intercoolers rely on thin tube-and-fin cores and crimped plastic tanks that fatigue quickly under heavy gross combined vehicle weight (GCVW) hauling and elevated boost. The CSF 6028 replaces these factory weak points with a rugged bar-and-plate design that acts as a superior thermal heat sink, keeping charge air temps significantly colder and denser under sustained load. Engineered as a direct drop-in replacement, it utilizes factory radiator core support mounting locations, lower rubber isolator perches, and factory charge pipe connections without requiring cutting or bracket modifications. It comes packaged as a complete bare intercooler unit; charge-air cooler pipes, silicone boots, and mounting isolator bushings are sold separately.

It fits all 2003–2007 Ford Super Duty F-250, F-350, F-450, and F-550 trucks and 2003–2005 Ford Excursions equipped with the 6.0L Powerstroke turbo diesel engine.

Fitment

• 2003–2007 Ford F-250 Super Duty 6.0L Powerstroke Turbo Diesel
• 2003–2007 Ford F-350 Super Duty 6.0L Powerstroke Turbo Diesel
• 2003–2007 Ford F-450 / F-550 Super Duty 6.0L Powerstroke Turbo Diesel
• 2003–2005 Ford Excursion 6.0L Powerstroke Turbo Diesel
• Heavy-duty bar-and-plate aluminum core provides superior thermal efficiency and heat-soak resistance
• Cast aluminum end tanks are 100% TIG-welded to the core to eliminate crimped plastic seam blowouts
• Withstands extreme boost pressures and high-torque thermal cycling under severe towing conditions
• Direct drop-in replacement engineered to factory OE core support mounting locations and dimensions
• Precision-machined inlet and outlet ports feature raised retention beads to prevent boot blow-off
• Direct upgrade replacement for OEM Ford part numbers 3C3Z-6K775-AA, 4C3Z-6K775-AA, and 5C3Z-6K775-AA
• Significantly lowers intake air temperatures (IATs) and exhaust gas temperatures (EGTs)
• Backed by CSF's 2-Year Limited Warranty

Park the truck on a level surface, engage the parking brake, and disconnect both negative battery cables. Allow the engine compartment and cooling system to cool down completely before disassembly. Remove the front grille assembly, upper radiator core support cover, and headlight bezels as needed to gain full access to the front cooling stack. Disconnect the hot-side (passenger) and cold-side (driver) intercooler boots from the intercooler inlet and outlet tank stubs using an 11mm (or 7/16-inch) deep socket. Unbolt and remove the upper radiator core support crossmember and upper intercooler retaining brackets. Carefully tilt the A/C condenser and secondary fluid cooler lines forward without opening or stressing sealed refrigerant circuits. Lift the factory intercooler straight up out of the lower chassis rubber isolator perches and maneuver it clear of the truck. Inspect the lower rubber mounting bushings in the chassis support perches; clean them thoroughly or replace them if dry-rotted or split. Transfer the factory upper mounting grommets to the CSF 6028 end tank brackets. Lower the CSF 6028 into the vehicle, ensuring the lower mounting pins seat squarely into the lower rubber isolator bushings. Reinstall the upper core support crossmember and torque the upper intercooler retaining bracket bolts to 18 ft-lbs (24 Nm). Clean the inlet and outlet necks of the CSF intercooler with brake cleaner and a clean lint-free cloth to eliminate any residual oil film or manufacturing residue. Reconnect the hot-side and cold-side charge pipe boots, making sure the boots seat completely past the raised retention beads. Position the constant-tension T-bolt clamps behind the retention beads and torque all clamp nuts to 9–12 ft-lbs (106–142 in-lbs). Reinstall the front grille, headlights, and upper trim panels, reconnect the battery cables, and perform a test drive under load bringing manifold boost pressure to 24–28 PSI to verify a complete, leak-free seal.