CSF 08-10 Ford Super Duty 6.4L Turbo Diesel Charge-Air-Cooler

Heavy-Duty Bar and Plate Charge-Air-Cooler Built for 2008-2010 Ford Super Duty 6.4L Power Stroke Boost Demands

The CSF 7105 Turbo Diesel Charge-Air-Cooler is a purpose-built drop-in replacement intercooler for the 2008-2010 Ford Super Duty equipped with the 6.4L Power Stroke turbo diesel. High intake air temperatures are a known weak point of the 6.4L Power Stroke under tow, performance, and high-boost applications, and the factory intercooler loses efficiency as boost pressure climbs. The CSF 7105 addresses this with a heavy-duty bar and plate core construction, all-aluminum cast end tanks, and a high-density internal and external fin design that maximizes surface area contact for superior cooling efficiency. Pressure tested at 120 psi, it installs in the OEM intercooler location using the factory quick-connect inlet and outlet connections with no modifications required. The unit is finished in CSF's Thermal Rejection powder coating in the factory-matched Black/Red and Silver/Black color scheme for an OEM-quality appearance.

Key Features

• Heavy-duty bar and plate core construction for superior strength and cooling efficiency compared to the OEM tube-and-fin design
• All-aluminum cast end tanks for maximum durability under sustained high-boost operation
• High-density internal and external fin design maximizes surface area contact for improved charge-air cooling efficiency
• Pressure tested at 120 psi for reliability in extreme boost applications including modified 6.4L Power Stroke builds
• Drop-in fit installation using precise OEM-style quick-connect inlet and outlet connections with no modifications required
• CSF Thermal Rejection powder coating in factory-matched Black/Red and Silver/Black for OEM appearance
• Purpose-built for the 2008-2010 Ford Super Duty F-250, F-350, F-450, and F-550 with the 6.4L Power Stroke

This Part Fits

Specifications

What Is Included

• 1x CSF 7105 Heavy-Duty Charge-Air-Cooler for 2008-2010 Ford Super Duty 6.4L Power Stroke

Frequently Asked Questions

The factory 6.4L Power Stroke intercooler uses a tube-and-fin core that becomes less efficient as boost pressure and airflow demand increase. Under towing loads, performance tunes, or sustained high-RPM operation, the OEM core allows intake air temperatures to climb, reducing power density and increasing exhaust gas temperatures. The 7105 bar and plate core maintains lower charge-air temperatures under higher loads, supporting more consistent power and reduced EGT over longer pulls.

Yes. The 7105 uses OEM-style quick-connect inlet and outlet connections that mate directly with the factory 6.4L intercooler plumbing. It installs in the OEM intercooler mounting location with no cutting, drilling, or modification to the truck or charge-air plumbing. The hardware and connection points are identical to the factory unit.

The 7105 is pressure tested at 120 psi, well above the operating boost range of any stock or lightly modified 6.4L Power Stroke. This pressure rating ensures the end tank to core joints and bar and plate construction will not fail under the higher boost levels produced by performance tunes, larger turbos, or compound turbo setups common on modified Super Dutys.

Yes. The bar and plate construction and 120 psi pressure rating of the 7105 make it suitable for tuned 6.4L Power Stroke applications running higher boost. The increased core density and surface area provide more cooling headroom than the OEM tube-and-fin core, which supports the higher charge-air flow demands of modified and tuned builds.

CSF's Thermal Rejection powder coating is applied to the exterior of the intercooler core and end tanks. The coating is formulated to improve radiant heat rejection from the core surface, helping the core shed absorbed heat faster when the vehicle is moving. The Black/Red and Silver/Black color scheme is matched to the OEM 6.4L Power Stroke intercooler appearance for a clean factory-look installation.

This intercooler uses all-aluminum cast end tanks with bar and plate construction, which is more structurally resistant to pressure cycling fatigue than the OEM plastic-tank or tube-and-fin designs. The 120 psi pressure-tested construction is substantially stronger than the factory unit. While no intercooler can prevent leaks from deteriorated boots or couplers in the surrounding plumbing, it is built to resist failure at the core and end tank level under extreme boost conditions.

CSF provides a manufacturer warranty covering defects in materials and workmanship. Contact CSF or your authorized retailer to confirm current warranty terms and any conditions applicable to modified or performance applications before purchase.

No special tools are required. The OEM quick-connect inlet and outlet connections release and reconnect using standard hand tools. The mounting hardware uses standard socket sizes. Installation time is typically one to two hours for a mechanically experienced owner.

Installation Instructions

1. Allow the engine to cool completely. The charge-air system is pressurized when the engine is running and hot.
2. Disconnect the negative battery terminal.
3. Remove the hood or prop it fully open for maximum access to the intercooler mounting location above the engine.
4. Locate the OEM intercooler at the top of the engine. Disconnect the quick-connect inlet coupler on the driver side and the outlet coupler on the passenger side by pressing the release tabs and pulling the couplers free.
5. Remove the intercooler mounting bracket bolts. Lift the OEM intercooler straight up and out of the engine bay. Note the orientation for reinstallation.
6. Lower it into the mounting location in the same orientation as the OEM unit. Reinstall the mounting bracket bolts and tighten to the factory torque specification.
7. Reconnect the quick-connect inlet and outlet couplers to the intercooler connection necks. Confirm each coupler clicks fully into the locked position and cannot be pulled free by hand.
8. Inspect all surrounding charge-air plumbing, couplers, and boots for cracks or deterioration while the intercooler is exposed. Replace any worn components before reassembly.
9. Reconnect the battery. Start the engine and verify there are no boost leaks by listening for hissing under light throttle and checking all coupler connections for movement.