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  1. #1
    ERICG1's Avatar
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    Removing stock intercooler

    Please help ! I am trying to remove the stock intercooler ( 2006 RXT ) and I have removed the two hoses and the collar holding it in but it still will not budge. What's the trick to jerking this thing out ? Any and all responses will get you a gold star ! Thanks in advance everyone !


  2. #2
    JFizzleJR's Avatar
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    have you loosened and/or removed the 7 bolts that hold the intake manifold to the block?

  3. #3
    Twist a little and pull.

  4. #4
    Richieb's Avatar
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    Take your time, no cussing... it dont help!!

    Two ways to do this.

    One is the manifold removal, which will take time, and could introduce other complications if one is not careful on the re-assembly.

    The other is to take out all the plastic parts for the intake so you will be able to pull it outward. It is around 18" in length, and will not come out unless square.

    The trick is to twist it as you pull it. I put a bar inbetween the two old pipe connectors to start it rotating.
    Get enough gap so you can ease it out with a few flat blade drivers. It will come almost out, then you have to wrestle the last 3.5" squarely out.

    Don't butcher the flange too much, but remember the inside edge is the sealing edge for the block-off.

    When you have done this you have to remember the seals at BOTH ends will need to be accounted for.

    Some models, typically the 07 and more recent have a big 4" O-ring, which may be left in there, BUT... There is a rubber seal which can, and does stay in the manifold as you remove the IC.

    I had one ski in that ran not quite right.... the rubber seal was still in there when I wanged the camera inside the manifold!!!, but it could have been much worse!!

    Get a camera, torch, and even a narrow wrist in there to extract it.

    Another point is to remember the hose under the exh manifold.... make sure it seals, and is secured.

    The flange seal clamp goes on one way, and is keyed via the slots in the clamp itself.

  5. #5
    ERICG1's Avatar
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    So I do not have to loosen the manifold bolts ??? BTW Thanks guys !!

  6. #6
    GOT BOOST? Dockside's Avatar
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    Quote Originally Posted by ERICG1 View Post
    So I do not have to loosen the manifold bolts ??? BTW Thanks guys !!
    no you dont have to... BUT you will have to undo the gas tank straps and remove the stock air box to slid the cooler all the way out of the manifold. Its a PITA to remove but just keep fighting with it... OH and +1 to what Richieb said....

  7. #7
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    To remove the IC on the RXT all u have to do is remove the hoses, and the clamp, then put a long screw diver between the pipes and give it a little extra leverage to twist the cooler loose and then pull it out slowly to keep the seals on the cooler and it will come right out no need to loosen or remove anything else the RXT has enough room between the tank, intake, and motor to remove it.

  8. #8
    ERICG1's Avatar
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    thanks everyone, BTW, JonnyRXT my parents live just north of you in Schuylkill Haven on top of the mountain with 77 acres of land.
    Last edited by ERICG1; 06-25-2010 at 09:39 PM. Reason: sic

  9. #9
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    Oh thats cool i visit that area alot to ride quads, and go jeeping!

  10. #10
    West Texas RXP skoepp's Avatar
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    Quote Originally Posted by ERICG1 View Post
    thanks everyone, BTW, JonnyRXT my parents live just north of you in Schuylkill Haven on top of the mountain with 77 acres of land.
    Did you get it out?

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