2nd generation intercooler

[formula]

John,

That is correct. When I installed the new intercooler I did not notice any differences. Things have changed since then though.



I don't think that it's a good idea to use the boost pressure to indicate horsepower. Too many variables here.



The reverse scenario is more accurate. You will need to have more boost as you add more fuel.



Sean

 

[Scot]

Originally posted by nascar mark

It will take some serious mods to make it fit. I was measuring this up 2 weeks ago. Hutchew is right. Supports on either side of innercooler will have to be modified and height is also a issue. My air conditioning is another hasel.

On my project, the word is to run the second gen cooler upside down. I haven't got that far so time will tell.

 

[jbolt]

Is the piping the same size on the 2nd gen cooler as the 1st gen cooler?

 

[formula]

Originally posted by jbolt

Is the piping the same size on the 2nd gen cooler as the 1st gen cooler?

No, it's larger on the 2nd gen cooler.



Sean

 

[backroad]

Larger Intercooler?

You kids might want to look at the newer Ford Powerstroke intercoolers for a 1st generation replacement. The Fords are taller and thicker, but the consideration would be that the hose connections are also a larger diameter.



This is the intercooler that I'm going to be using on my Cummins swap into my '87 Ford, crewcab, dually, 4X. I'm also using the first generation Dodge's radiator and the Ford intercooler fits perfectly on both sides of it. Adapting the hose sizes is not that big of a deal. The Ford intercooler appears to have almost twice the volume of the '93 Dodge.



You might have to search a little for the Ford cooler. I understand also, that Ford has now switched over to the plastic tanks, so you'd have to find the all aluminum versions to handle any boost over about 30 lbs.



Just a thought...

Backroad in Arizona...

 

[Clarkoh]

Great information

Worth bringing back to the top of the forum!

 

[CKnoop]

I am going to try to put a 2nd gen intercooler in my 84 crewcab swap my doner truck is a 89 so it dosnt have one at all I got one from a 98? for 50 bucks. has any one done this swap? innercooler that is. my core support dosnt have any holes in it so I know I will have to cut it up and do a bit of welding. Havn't started the swap yet very soon going to pull the 440 out next weekend local cruse this weekend

 

[dpuckett]

I have been considering putting a 2nd gen cooler in my 91. I picked up the hoses, pipes, and clamps at a junkyard for $20. They are stock, but still a steal. INtercoolers go for $100-300 from yards- depends on your relationship with them, and how in demand they are. Here demand is low, hence some stuff is cheap. I woudnt go through the trouble fo swapping it out without getting it tested to at least 50 psi. THere was a post here a while back about the differences between 1st gen and 2nd gen intercoolers. Hoses and pipes are LOT bigger than first gen. I figure since I have to cut, weld, and stuff things in front of the grille, why not go for a bigger, better flowing cooler? At least one would think it'd flow better with the bigger core, bigger inlets and outlets, and bigger piping to and from the cooler.



Nascar Mark- this might be more appropriately PM'ed, but someone else might find this useful. What is the maximum efficient boost level for a PDR HX35 without an intercooler? With the 18, I oculd hit 30 at sea level, slight haze. I put a 12 on it (I drive 95% empty now), and can hit 35 on the flat, no smoke. (I know, I need to hook up the wastegate. ) No real hills here, and havent put a load behind it. Cant really load it up before running out of RPMs.

 

[Paul Herioux]

Keeno, thanks for PM'ing me about this thread. It must have slipped under the radar last year as it was started during the school year. I'll keep the answers short this time around as I should be grading papers and writing progress reports right now.



Hopefully I will have time a Christmas break to edit the pictures I took of my install so they will fit in the gallery section.



I installed a 1995 intercooler and an HX35W with all of its plumbing out of a 1996 truck. The intercooler wasn't bad to install, took about 8 hours of work to cut it in. I believe the non-intercooled radiator support is actually easier to work with as it is a lot flatter. The downside is I haven't been able to figure out a way to make a stock A/C condenser fit with this set up. I will definetely be figuring something out when I get going on the 73 crewcab. One way or the other it WILL have A/C.

For you guys(and gals) with the auto's you will have to ditch the stock trans cooler. I replaced it with a B&M plate style cooler with 1/2" fitting from Summit.

The secondary hood latch needs to be shortened to clear the I/C and the latch supports need to be modified. I have very detailed pictures of these mods which I will post in my gallery as soon as I find the time.

The stock pipes and couplers from a second gen work good. The I/C to intake pipe needs a 15* bend about a third of the way up to clear the battery tray. Good muffler shop can do this in about 45 seconds. Not as good as a mandrel bent pipe, but the price was right.

The only real snag with the turbo is the cold outlet elbow. The one used on the second gen's is to long to clear the frame rail. I clocked the cold housing around to run the turbo to I/C pipe over the inner fender and under the airbox to turbo hose. Its a tight fit and is rubbing the paint off of the inner fender. I am in search of the correct elbow and will post the P/N when I find it. You will also need the a/b to turbo hose from an intercooled first gen unless you plan on a BHAF setup.

More to come,

Paul

 

[Scot]

Paul, is the condensor problem due to a lack of depth between grill and intercooler? I ask because I am still trying to hammer out my core support?

 

[McGivern]

I bought a 2nd gen on ebay and tried it. It was too much work. The good news is I sold it for slightly more than I bought it. After that and hearing the Banks doesn't do squat, I've just continued running the stock cooler. I think it proved better to invest in a wastegated HX-35, BHAF, and 4" exhaust. My truck probably only has 230-240 HP with the mods, but it pulls the grades just fine with a descent size boat and I haven't fried my Get-Drag yet (65,000 mi since overhaul). My two cents worth.



Mark

 

[therabbittree]

i just mounted a 2nd gen intercooler in my 89 but i did it a lot differenat then normal, i mounted mine upside down so the inlet and out let are on top tomake access easier etc. . i also have a swapped in crossflow later 1st gen radiator . . my truck has no ac etc so that wasn't a problem and i ditched the hood latch for hood pins, i have to cut a bunch from the radiator support and i made new lower supports fso i can pull the cam with out cutting teh support now. . also notched the lower part of the support to access the crank shaft bolts easier, i have plans to make the top part of the core support removeable ie unboltable so if i pull th eengine i can slide it out through the front easier etc. . no im trying to figure out the plumbing and piping the oulets and inlets are 3. 75 " which sucks as its a non satndard size arg hi bought 3. 5 and 4" marine exhaust hose to use and neither fits i really didn't want to spend 200 plus $ for piers boots especailly since teh angel is wrong for me know that im flipped upside down . . im deating on welding a slight ring to teh outlets so that are 4"... mummn ... oh and i also had to make the battery tray moved over on a angel to clear the intercooler enought to make access easy etc. . i will post some pic if people want to see it etc?

thanks deo

\x/ hillfolk!

 

[DPKetchum]

I did post the Banks intercooler did'nt do squat BUT after mods and INJECTORS and Fuel being turned up I think it DOES do squat then. My 93 was so so with all kinds of mods until i replaced injectors. THEN it rocked with keeping egt in a low range. Towing 10k floored never could pop 1000 degrees and it was faster then the 03 H. O. I own now. Got better fuel mileage also.

 

[Clarkoh]

What was your choice for new improved injectors??

How big is too big? I have been advised that POD's are too much, especially for pulling my big trailer. What was your choice?



Anybody have advise?

 

[DPKetchum]

I was told PODS were too much for towing etc. I bought a set of industrial injectors from ADVANCED DIESEL TECHNOLOGIES for less then POWERWAGONS. They were rated at a 45H. P. increase. Low smoke,ran great pulled hard. They have a WEb site. Talk to DOUG. He's s great and will explain why not to use PODS for normal driving and especially towing.

 

[Clarkoh]

Thanks

I will do that.