Tucked between the battery and the radiator, buried beneath a tangle of coolant hoses, lies the heart of the Ford Powerstroke 6.7L charge air cooling system. This chunk of aluminum, the air-to-water intercooler, is responsible for keeping your workhorse breathing easy.
When we looked at this project last, we outlined what makes air-to-water intercoolers different from your typical air-to-air intercooler and why they're used in heavy-duty applications. We also took our waterjet cutter to our brand-new OEM intercooler to see what was going on beyond the bland exterior. Once we had evaluated the stock intercooler's strong