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It's now time to install our prototype and put some data behind the efficiency differences we expect to see between our cooler and the factory heat exchanger. We did add a substantial amount of core surface area, so we anticipate that heat transfer will improve during a load test. Check out this shot of the Mishimoto 6.0L transmission cooler installed!

Mishimoto 6.0 Powerstroke transmission cooler installed

Testing Process

We have numerous tools at our disposal to test heat exchangers. For this one, we will be using our Dynapack™ dynamometer. With a transmission cooler test, we want to apply some load on the vehicle to ensure that stress is created within the drivetrain. We can set the Dynapack to apply a specific load to achieve this.

Mishimoto 6.0 transmission cooler testing

We then set up our truck for some runs on the Dynapack!

Mishimoto 6.0 transmission cooler testing

We installed pressure and temperature sensors within the transmission inlet and outlet lines. This will allow our team

Now that we have designed our 6.0L transmission cooler prototype in SolidWorks®, our team has begun work on constructing our first prototype. We will be using this prototype to verify fitment on our truck and perform heat-soak testing to determine any cooling benefits provided by the larger core size.

Mishimoto 6.0L Transmission Cooler Prototype

Check out a couple shots of our first prototype unit!

Mishimoto 6.0 Powerstroke transmission cooler

Mishimoto 6.0 Powerstroke transmission cooler

Mishimoto 6.0 Powerstroke transmission cooler

Size Comparison

We are increasing the size of this cooler for greater fluid capacity and improved heat transfer. Although the core height remains the same, we've increased the width to provide greater surface area for airflow. Check out a couple shots showing a size comparison of our cooler against the factory 31-row unit.

Ford 6.0 transmission cooler size comparison

The next two images will give you a better idea of the additional width we've added with our

If you follow our Ford Powerstroke 6.0L product line, you are aware of the high- and low-temperature thermostats we released last year. The high-temperature unit quickly became a customer favorite as a reliable way to improve engine operation, in-cabin heat, and fuel mileage. These benefits are particularly useful in the cold-weather months. Our low-temperature thermostat offers a lower recovery temperature compared to the factory unit, which can help keep coolant temperatures regulated during towing or when transporting heavy loads.

During the release of the thermostats, we had numerous requests for a replacement housing. The factory housing is a casted piece, which isn't aesthetically pleasing, but it is easy to replace.

Product Development

Development began in a pretty simple fashion. We acquired an OEM housing and started capturing measurements so that we could reverse-engineer the piece.

Factory 6.0L Powerstroke thermostat housing

After some tedious design work in Solidworks, we soon

The factory inlet/outlet portions of this intercooler are quite interesting. They are shaped to route around the radiator support; however, this has a significant impact on the airflow through this part of the cooler. This bottleneck cannot be eliminated unless users want to grab the Sawzall and shred some steel. We will be looking to reduce this restriction as much as possible with our design. Here is a look at the factory setup.

Factory intercooler outlet

Factory intercooler outlet

And a close-up shot of the tube-and-fin core.

Factory intercooler core

Factory Intercooler - Basic Dimensions

A couple dimensions are shown in the images below to give you an idea of the size of the factory cooler, assuming you've never measured yours!

Factory intercooler thickness