This will fit in all pre 07 medium duty kodiak chassis .

The intercooler from 07 kodiaks bolts directly in all pre 07 : 06,05,04.5,04 -4500/5500 's with dmax and plastic intercooler tanks .

This part # is the all Aluminum Intercooler out of 07 and later kodiaks .

GM PART # 15843434

All aluminum welded tanks to core . Core is thicker on later 07 cooler by almost 1/2 " .

To install this you drill out the rivets for brackets they put on 07 and later intercooler and use all your original trans cooler/ condersor brackets . You just need to add a 1/8 " spacer behind brackets on bottom mount for trans/condensor mounts .

I do mine with the hood off , its just easier and also very easy to take hood off . Makes getting in and out a breeze . Can be done with hood on , just a pain . You have to release driverside hood cable hold to do with hood on .

Thats it , it is direct bolt in . Good find for all kodiak owners .

I will follow this thread and anybody needing any help doing this can PM me or call me . 714-514-3675 .

07 cooler comes with 4 brackets for trans cooler/ condensor mounts . I drilled the rivets out and discarded . Didnt need them and used original mounts that are seperate.from intercooler . Only thing added was 2 washers behind lower condensor/trans cooler brackets to space for extra 1/2 of core thickness . Needed on bottom mounts only behind bracket to frame . In one of the pics you see me with 2 washers in hand showing where to add . If you wanted to use with 07 brackets you can . It eliminates original condensor bracket . It does make it quite a bit more difficult to get in this way and I think the original bracket is stronger and better for reinforcing the trans cooler mount . My opinion .

I would recommend this to all pre 07 kodiaks as a good upgrade . The core is almost 1/2 " thicker and the tanks look much better inside for flow .

I would describe it like going from a 3 core to a 4 core radiator . Dont expect any real hp gains . I dont see huge difference and wouldnt expect it to be . It still has to be more efficiant . I might be nuts but It seems like I am about 50-75* cooler at cruise on race tune and I get to 1600 slower and can hold it on longer it seems before I get to 1600* . I havnt towed with it yet or run a small tune on it . I will and report back . It sure looks good through the grill over that plastic pile .

Either way it is a upgrade over the recycled milk carton cooler .

http://www.dieselplace.com/forum/attachment.php?attachmentid=83726&thumb=1&d=1239266027 (http://www.dieselplace.com/forum/attachment.php?attachmentid=83726&d=1239266027)

http://www.dieselplace.com/forum/attachment.php?attachmentid=83727&thumb=1&d=1239266027 (http://www.dieselplace.com/forum/attachment.php?attachmentid=83727&d=1239266027)

http://www.dieselplace.com/forum/attachment.php?attachmentid=83728&thumb=1&d=1239266027 (http://www.dieselplace.com/forum/attachment.php?attachmentid=83728&d=1239266027)

http://www.dieselplace.com/forum/attachment.php?attachmentid=83729&thumb=1&d=1239266027 (http://www.dieselplace.com/forum/attachment.php?attachmentid=83729&d=1239266027)

http://www.dieselplace.com/forum/attachment.php?attachmentid=83730&thumb=1&d=1239266027 (http://www.dieselplace.com/forum/attachment.php?attachmentid=83730&d=1239266027)

Again thanks burbanman for the part # off your truck .

Anybody wanting to do this , use the part # GM PART # 15843434 .

If you need help get ahold of me . I can walk you through the whole procedure step by step . Most important to look at where your intercooler clamp studs are located on both sides before removal . Your hood will hit clamp studs if not positioned and clocked correctly . Also you have to manipulate one of the A/C lines a bit to get intercooler in and out driver side of truck . A/C line needs to be bent some to give clearance to get intercooler out . This is easily done with some finesse . You need to pay close attention to detail cleaning connections and getting everything back in its place . It is easy to do A/C line and bend back in place . If you are not comfortable with that you can discharge and remove line and recharge A/C after finished . Getting the coolers in and out and attention to not beating the cooler core or fins on anything is the most important thing to me . You'll be pissed when you look at your new cooler and see a bunch of fins pushed sideways . It is best to install with 2 people . I barely brushed a few on mine and straightend easy . Take you time . Getting cold side tank outlet to clear between trans cooler/condensor and radiator to go out driverside is the tight part . It will clear with no room to spare . You have to hold condensor/trans cooler up and away at same time as manipulating cold side out betwen these things , with another person holding hot side inlet guiding intercooler in and out for you from driverside .

If none of this makes sense call me . 714-514-3675 .


Johnny

This is a pic of plastic intercooler before I took out old motor to compare .

83791

You did not list 03, do you think it will fit in mine, 2003 GMC C4500 ??

Yes forgot 2003 . Same chassis all years .

2003 Also can use this intercooler .

There is a bracket unused that maybe one of the 2007 or later model guys can tell us what is mounted there . I left it on and did not cut it off . It isnt in the way of anything . All aluminum on driver side tank bottom .

83800

Thanks for the info. I am wondering how long the plastic ends will hold up on the one we built a twin turbo system for.

Sorry for the interuption from ROLNCOAL, now back to your regularly scheduled programming.

Sorry for the interuption from ROLNCOAL, now back to your regularly scheduled programming.

Thanks Brother

Thanks for the info. I am wondering how long the plastic ends will hold up on the one we built a twin turbo system for.

I figured this was deserving its own thread . Ive wanted a aluminum intercooler since the day i bought mine . Finding the 07's had this is a score .

Im so jealous of the twin set-up you did , How has it come along tuning wise ?

This may be a two fold benefit for me. My truck did not come with the "Optional" transmission cooler. So....if this new intercooler has tabs for a trans cooler, I may be in business. I have found an aftermarket tranny cooler that will flow what an Allison needs, and I have just been looking for a way to get it mounted.

Thanks for the info gasuout, gonna have to order one of those. I've been wanting an aluminum intercooler for mine as well :rolleyes:
Love your light set up too.....do they limit air flow to the coolers?

I figured this was deserving its own thread . Ive wanted a aluminum intercooler since the day i bought mine . Finding the 07's had this is a score .

Im so jealous of the twin set-up you did , How has it come along tuning wise ?

We are making good progress. Hopefully we will pull my truck down to TS with it. We will get some dyno numbers before then. I have to keep the owner under control and told him to keep it under 50 PSI until we get head studs in it, which will probably lead to rods and ... :rolleyes:

Thanks for the info gasuout, gonna have to order one of those. I've been wanting an aluminum intercooler for mine as well :rolleyes:
Love your light set up too.....do they limit air flow to the coolers?

I saw no change in trans temps or noticed any drawbacks from lights up there in front . The bar is really strong . Bolt on . Made so you retain tow hooks and no obstruction to them .

Defiant Truck Products : makes the light bar . They are made per order from a jig he has from mine . Paul Fox . Good guy and does really stout stuff . PM me if you cant find it on google .

Just tell him your a friend of Johnny's if you call him .

Yes forgot 2003 . Same chassis all years .

2003 Also can use this intercooler .

There is a bracket unused that maybe one of the 2007 or later model guys can tell us what is mounted there . I left it on and did not cut it off . It isnt in the way of anything . All aluminum on driver side tank bottom .

83800


Not sure What goes there John, as my truck has every optional cooler offered on an 07, and my truck is just like yours with nothing at all in that bracket.

I am wondering if maybe the intercooler also fits the 65-75-8500 series trucks also, and is so, maybe the Cat or Bigger dmax has some other cooler that goes there, possible PS?

I guess that means the next question: Any one with a 6500 or bigger truck have the same cooler, and tell us what is there? LOL

John,
whats the price of the new unit? Sounds like an easy install, if the price is right I need one.

I go t mine for 391.00 here at toms truck center in santa ana . some others said they looked it up on gmpartsdirect.com and found it for 264.00

It lists for 900.00 , It is easy bro . If you do it and need any step by step . Call me .

714-514-3675 .

nice, I'm going to order one tomorrow. When I get it I will call you if I have any problems with the install. Thanks John

anytime , i'll give you the easy no hassles way to do it .

I go t mine for 391.00 here at toms truck center in santa ana . some others said they looked it up on gmpartsdirect.com and found it for 264.00

It lists for 900.00 , It is easy bro . If you do it and need any step by step . Call me .

714-514-3675 .

Does anybody know the part # for the 4 gauge plastic cluster on the right side of the dash. The one that eliminates the cubby and adds 2 more gauges

John,
Did you upgrade your oil cooler or tranny cooler? I got the new inercooler and am going to start working on it this week. I'm thinking though why I'm at it I should upgrade those to bigger and or better units. Anyone done this? I put the 4 gauge cluster in I will look for the part number.

Does anybody know the part # for the 4 gauge plastic cluster on the right side of the dash. The one that eliminates the cubby and adds 2 more gauges

When I did mine I just called a GMC dealer and they looked it up.It fits a 4500 4X4. You can also call PPE, because I called and gave them the part # awhile back. When you get the panal you need to make a alum. plate to mount the 4 gauges in. The plastic is not that strong. I did it for mine and it worked great.

I didnt use a plate to mount my guages and have had no problems with it.

I didnt use a plate to mount my guages and have had no problems with it.

Without the plate my gauges all pointed a different direction. Glad yours was made better than the one I got. Buy the way great looking truck, love the color!!!!