The KC Turbos 302291 is a heavy-duty, high-performance all-aluminum 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. Designed as an extreme-duty direct drop-in replacement for the OEM unit, this intercooler features a high-density, TIG-welded bar-and-plate core that is 25% thicker than the stock core. Furnace-brazed and welded directly to heavy-duty high-flow cast aluminum end tanks, it eliminates the leak-prone plastic tanks and crimped mechanical seams found on factory coolers. Tested and rated to withstand sustained pressures exceeding 120 PSI, it delivers superior heat dissipation and maximum thermal inertia to prevent heat soak during heavy towing, hotshotting, and aggressive performance tuning.

Catastrophic plastic end tank blowouts along factory crimp seams, boost leaks past degraded tank O-ring seals, heat-soak power loss during long uphill pulls, 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 KC Turbos 302291 replaces these factory failure points with a rugged bar-and-plate core and cast aluminum end tanks engineered to withstand extreme boost pressures and thermal shock without splitting or leaking. Designed as a true 100% drop-in upgrade, it retains factory radiator core support mounting perches, lower rubber isolator positions, and charge pipe locations, making it fully compatible with both OEM and aftermarket boots and charge pipes. It comes packaged as a complete bare intercooler unit; charge-air 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 core is 25% thicker than the factory intercooler for superior thermal efficiency
• High-flow cast aluminum end tanks are 100% TIG-welded to the core to eliminate crimp seam failures
• Extreme-pressure rating tested to withstand over 120 PSI of boost
• Direct 100% drop-in replacement engineered to factory OE core support dimensions
• Fully compatible with factory original equipment (OE) or aftermarket boots and charge pipes
• Precision-machined inlet and outlet ports feature raised retention beads to prevent boot blow-off
• Significantly reduces intake air temperatures (IATs) and lowers exhaust gas temperatures (EGTs)
• Backed by KC Turbos' 1-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 stack 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 KC Turbos 302291 end tank brackets. Lower the KC Turbos intercooler 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 KC Turbos 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.