2nd gen intercooler install.

[KOG]

Searched the forums as best I could and can't find any details for this. Parting out a 96, already swapped the 4.10 rear axle into the 91.5 which was 3.54, already have a 47RH installed. Also looking at a front hub swap to get 9/16 studs, bearings are the same, rotors look similar, is this possible? Obviously the 2nd gen intercooler is larger, what has to be cut cut and/or fabricated to make it fit?

 

[DVolk]

Look at Roberts post on the ultimate crew cab he has a gen 2 cooler in his crew cab , but I can testify a gen 2 intercooler helps a lot I used a gen to intake too , my gen 1 body went south so I put my gen 1 in a V10 truck

 

[KOG]

That's a very nice truck, but nothing is shown on the intercooler install. I can do this on my own if necessary, but it would be nice to know if some else has worked out the details. It's obviously not a bolt in.

 

[RWherley]

Its not as detailed a post as I thought but this has some of the basics of i did when i did my truck

https://www.turbodieselregister.com/threads/244213-Total-air-system-upgrade

If you need other information ill help if i can

 

[RSchwarzli]

Yeah the crew cab should have some but you will find more on the The 90s conversion. I think all you will need will be here:

https://www.turbodieselregister.com...nd-Modifications-WARNING-LOTS-of-Pics!!/page4

 

[KOG]

Thanks guys, now that give me an idea of what's involved. I had the front end apart doing the KDP and figured this would be a good time to swap the intercooler. Maybe not so much . I'll have a very close look at whether it's going to be worth the effort on my truck. First project today, after front suspension bushings yesterday, is seeing if 2nd gen wheel studs will fit 1st gen hubs. I've determined that the full hub will not interchange even thought the bearings are the same because the seal on the 2nd gen hub is smaller to match a smaller spindle at the seal.