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Glad to see all the responses and good discussion!

I think the best answer is a half as tall Full Race/Cobb intercooler. It would still allow fresh air to part of the AC condenser, allow for a winch to be mounted, allow fresh air to the transmission cooler and still be 2x as good as the stock IC. This is the route I will be going.

Do any of the *** heat exchanger stacks have a tranny cooler second?

I respectfully disagree. Quoting 5 degrees is nonsensical because you aren’t saying under what conditions. The temp rise is based on

1) The mass airflow rate of ambient air through the grill and into the intercooler (which is related to vehicle speed) and how laminar/turbulent it is

2) The ambient air temperature

3) mass flow rate of compressed airflow inside the intercooler

4) the temperature of the compressed air through the intercooler (based on the current adiabatic efficiency of the compressor)

This is all for a specific intercooler so I’ve left of surface area, materials conductivity, pressure drop, etc.

I don’t think diesels are a good comparison because they don’t have to worry about high temperatures causing engine knock. Intercooler on diesels are to recovery air density (and maybe lower EGTs?).

I would also like to point out that trucks, unlike most cars, may see high load (I.e. high intercooler temps) at slow speeds. Since the temp drop of the compressed air and the temp rise of the ambient air is dependent on speed, this is a major consideration.

While I’m not suggesting that you agree with me solely because of it, I do have my masters in Mechanical Engineering and thermodynamics and heat transfer are my specialities.