The CSF 6013 is a direct-fit OEM replacement heavy-duty 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. Built to meet and exceed original equipment specifications, this intercooler features a high-efficiency aluminum tube-and-fin core furnace-brazed to heavy-duty, reinforced cast aluminum end tanks. Unlike factory and cheap replacement units that utilize failure-prone crimped plastic end tanks with internal rubber O-rings, the CSF 6013 employs 100% all-aluminum, TIG-welded construction. This robust configuration withstands sustained elevated boost pressures, extreme temperature swings, and the harsh vibration cycles common to heavy-duty diesel towing applications.

Catastrophic end tank separation along factory crimp seams, boost leaks past degraded tank O-ring seals, cracked plastic tanks, sluggish throttle response, high exhaust gas temperatures (EGTs), heavy black exhaust smoke under acceleration, and continuous loss of turbo boost pressure are what this core cures. On 6.0L Powerstroke trucks, early factory intercoolers equipped with plastic end tanks or fatigued aluminum crimps frequently blow out under aggressive acceleration, heavy gross combined vehicle weight (GCVW) hauling, or high-performance aftermarket tuning. The CSF 6013 eliminates all crimped plastic failure points with solid cast aluminum tanks welded directly to the core. Engineered as a drop-in OE replacement, it reuses the factory radiator core support mounting brackets, lower rubber isolator bushings, and stock charge-air duct locations without requiring cutting, drilling, or chassis 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 all-aluminum construction eliminates brittle OEM plastic end tanks and crimp failures
• Reinforced cast aluminum end tanks are 100% TIG-welded to the core for leak-free boost retention
• High-efficiency tube-and-fin core design maximizes heat transfer and lowers intake air temperatures
• Direct drop-in replacement engineered to factory OE dimensions and mounting locations
• Precision-formed inlet and outlet ports feature raised retaining beads to prevent boot blow-off
• Direct replacement for OEM Ford part numbers 3C3Z-6K775-AA, 4C3Z-6K775-AA, and 5C3Z-6K775-AA
• Pressure-tested to ensure reliable performance under heavy towing and aggressive tuning
• 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 intercooler upper retaining brackets. Carefully tilt the A/C condenser and power steering/transmission cooler lines forward without opening the sealed refrigerant lines. Lift the factory intercooler straight up out of the lower rubber isolator mounting 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 6013 end tank brackets. Lower the CSF 6013 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 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.