Doesn't let me edit but did want to share some more of what I learned in case someone else may come across it:
Here...follow along...

http://www.roushperformance.com/part...008-401633.pdf

Some observations for anyone else with this kit.

Page 15, I am missing one of 77 or 76, instead, I got a tube with a 90 degree bend in it.
Part 91 on page 16 was also swapped out for a different style bracket that appears to move the pump higher, the pump is also swapped for a unit with a different bracket on it. You will need to buy bolts to mount pump to bracket, they are not included. I needed to mod my bracket to get away from the clearance issues I was having with the trans cooling lines.
Part 98 I should have 2 of for the part 91 replacement and have 1.
Page 61, I do not have this kind of spacing between my rad and core support
page 63 and 64, their paper diagram mounts the pump too high into the hard lines for the trans cooler.
page 65, the wrong bracket is pictured, the replacement puts pump up 2" higher.
page 67 note the pcv hose step b, this uses the T hose, the PN on the part tag does not match part called out for instructions, compare against parts list.

 

So you mounted the HE between the Rad / Condenser?

Do you have the row pack with cooler out front?

 

I do. The instructions call for it to be located there.

 

Yeah I originally put mine in the oven as well.

Once you get the other problems sorted IDE throw it out front.

Oh and mine came with a GT500 IC pump bracket so cannot help you with that. We just eyed it in for the best fit on the Drivers Frame rail.

I found better judgement over the instal manual. Am sure you will figure it out.

 

Yeah an what's your engine code? May 08 is good. I run mine on Mobby Sync 1 and its quite as a mouse.

I can post a pic of the HE as long as you don't 'Facepalm'

 

Sure I'd like to see how you mounted it. I saw some mounted where the trans cooler is.

I heated my pump bracket up and bent the bottom part back and bolted it to the bottom side of the frame rail. Been fun...I'd rather do another blower install than headers...

 

Pretty much the same deal I had with the pump mount.

Anyways here is the HE.



I have a KC so this location worked better plumbing wise.

 

I am having a hard time understanding the instructions to mount the HE between the condensor and rad. For one there is no room there. Two that puts you risking damage to anyone of those 3 parts during the install. And third what kind of cooling do they expect the intercooler to recieve this close to these extreme heat sources. Heat from the rad and condensor is just going to radiate to the HE and make it enefficent at it's job. The HE should be out front. Thats the case on any other applicaion including factory SC'd vehicles.

Mine is also out front. I mounted a second heat exchanger just below the trans cooler to further improve my temps. I used an F250 trans cooler. Worked like a charm with it's insanely long mounting arms. Here are some pics.
http://www.f150online.com/forums/mem...2000s-f250.jpg

http://www.f150online.com/forums/mem...178455-361.jpg

http://www.f150online.com/forums/mem...178454-358.jpg

http://www.f150online.com/forums/mem...178453-356.jpg

 

For now I want to get this thing running then will look at other options. Got more than I anticipated into it...

 

Yep. Get use to that. Part of being in the forced inducted world.