This is more of an info thread/done today, so admin feel free to move it.
I have done a fair bit to looking around for replacements for my famously popular leaking 3L Intercooler. After the initial call to Nissan and the ridiculous asking price for the factory unit and the inevitable future failure, I have found two great options that I thought I would share. The two options are more based around your financial situation and amount of time spent in low speed high rev situations.
Option 1. Cross Country 4x4 - GU Patrol 3.0L Intercooler Upgrade - $1250
These units seem like an ultimate option with a much bigger core and thermo fan. (Note this requires some alteration of the intake scoop rubber and I assume the plastic engine cover doesn’t fit back on. Don’t be afraid though as this seem relatively simple) With a thermo fan installed underneath the core this should remove airflow blockages caused by the usual top mount fans at higher speeds. They use a PWR developed core (from my understanding PWR do most of the V8 racing car cooling).
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Option 2. PWR Performance Products - Patrol 3.0T Changeover Top Mount - $649
This product is an exchange based system where they take the tanks of the old unit and replace the core with a new one (Better Quality, same physical size) and TIG weld it in. These are an exact replacement for the original so no modification is required.
This one was my end choice due to financial constraints and the lighter offroad use due to it being my daily drive. I had the luxury of them being based at Ormeau QLD, which is close to me. For others they offer in most cases an advanced replacement option of leaving a deposit until your original unit is delivered to them. I have also found a company offering these units with the PWR core on ebay for around $599, but by the time I paid freight back and forward it was about the same and I could get an instant replacement.
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Original Factory unit to compare:
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