The Mishimoto MMINT-F2D-03SL is a direct-fit, high-performance 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 a rugged upgrade over the factory unit, it features an all-aluminum bar-and-plate core paired with heavy-duty cast aluminum end tanks that are 100% TIG-welded to eliminate the leak-prone plastic end tanks and crimped gasket seams found on OEM coolers. Finished in a durable sleek silver powder coat, this intercooler delivers substantial increases in core volume and fin surface area over stock, significantly dropping intake air temperatures (IATs), lowering exhaust gas temperatures (EGTs), and supporting sustained high-boost pressures under heavy towing or aggressive performance tuning.

Catastrophic plastic end tank blowouts along factory crimp seams, boost leaks past degraded internal tank O-rings, 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 construction and crimped plastic tanks that fatigue quickly under heavy towing duty cycles and elevated boost. The Mishimoto MMINT-F2D-03SL replaces these failure-prone factory components with a heavy-duty 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 drop-in replacement, it utilizes factory radiator core support mounting locations, lower rubber isolator perches, and factory charge-air ducting 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 core provides superior heat transfer and resistance to heat soak
• Cast aluminum end tanks are 100% TIG-welded to the core to eliminate crimped plastic seam blowouts
• Durable sleek silver powder-coated finish protects against underhood corrosion and road debris
• Direct drop-in replacement engineered to factory OE core support mounting locations and dimensions
• Significantly lowers intake air temperatures (IATs) and exhaust gas temperatures (EGTs)
• 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
• Backed by Mishimoto’s Signature Lifetime 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 Mishimoto MMINT-F2D-03SL end tank brackets. Lower the Mishimoto 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 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.