7.3L Powerstroke Intercooler in 91.5 question.

[Ncostello]

I understand a 99-2002 intercooler from a SuperDuty will fit in location without much hassle on my 91. 5 intercooled D250. However the inlet/outlet is 3" compared to my 2. 5" tube and boots. Does anybody make a 2. 5" to 3" intercooler boot to adapt? I'd rather not deal with new tubes, intake horn, turbo housing etc to upgrade to a 3" system.



Thanks!!!!!!

 

[Leper]

PAGE 3

They have all you will need at airflo.com

 

[dpuckett]

Heck, if you got it all apart, go to a 3" intake system all the way. It will allow more airflow, and help keep EGTs down. Replace the elbow off the turbo, get a 24v intake, and some hoses and pipes, and you're god to go. I plan to do that very soon. Just as soon as I find all the boots and clamps i need.



Daniel

 

[Niki]

Doing a 3" setup on our trucks is very simple. you can use a banks elbow, or I think cummins used 3" air horns in some apps. On the turbo side, I'd weld a 3" elbow to the turbo housing and its just a straight pipe from there. on the intake side, a 90 and a 60 or 75 degree bend should do it. Ebay has tons of cheap aluminum piping, and many vendors also have 3 to 2 1/2 couplers, hump hoses, etc.

 

[Ncostello]

I have an automatic... so I've also got the trans cooler up front. I realized this might cause a problem last night when I removed the grille shell. At least a relocation looks necessary.



And I've got to engineer some new condenser brackets I'd say at least.

 

[Leper]

Put it in front of the condenser.

Here is how.

One Way to Install a Powerstroke Intercooler - Dodge Diesel - Diesel Truck Resource Forums

 

[DanaLittle]

I installed a 99 Ps I/C in my truck and I used the I/C tubes and intake horn off of a 2002 dodge. Everything went i very easy. I relocated my little transmission cooler to below bumper. Do a search for Larger intercooler for pics

 

[sdstriper]

I don't remember the cutoff year but the later PS I/C end tanks are plastic. You want the aluminum end tanks, the early years had them.

 

[Shadrach]

Does anyone have the OEM part number from one of these PS coolers? Shadrach

 

[DVolk]

7.3L Powerstroke Intercooler in 91.5 Question

If your tight on BUCK$$$$$$$$$



go down to your local Home depot , or Ace Hardware



and go to the sewer drain pipe derartment



They have lots of rubber/poly urthane molded hoses ,elbows T's and

bell reducers and they work fine



I got them on my burb conversion with no hassels on the air intake tube

 

[TJarecke]

I believe all the 7. 3s were alum. So you are looking for an intercooler from 99-02. The 6. oh-nos had plastic ends, and their dimensions are different too. I am getting ready to put one in my buddies 1st gen too.

 

[dpuckett]

Some of the 7. 3s had plastic tanks, too.



DP

 

[TWorline]

If your tight on BUCK$$$$$$$$$



go down to your local Home depot , or Ace Hardware



and go to the sewer drain pipe derartment



They have lots of rubber/poly urthane molded hoses ,elbows T's and

bell reducers and they work fine

Then after you get that un-reinforced rubber hot an throw 30+ psi to them and they blow (ever blow a reinforced radiator hose at 15psi?) you can then get the good silicone couplers/reducers & don't forget the t-bolt clamps!

 

[DVolk]

7.3L Powerstroke Intercooler in 91.5 Question

There is some thing drasticly wrong if you get your intercooler or

air inlet tubeind/rubber hot enough to melt , if it does that the rest of the engine is junk as well . So you just a well keep your foot in it till it rains parts under your truck .



Fact only reaso why hoses burst on radaitors is that they basicly get rotten

in the first place , Ive been around the radaitor buisness for 20 plus years

and never seen new hoses burst for no reasons other than blocks or being rotten .



Oem equiptment dont put silicone hoses on there rigs and they work fine

and have been doing so for years before the new stuff .



This goes for the large truck manufactors as well .



But if you got deep pockets buy the highpriced stuff and keep the aftermarket



makers in buisness



Gee only 30 pounds psi hmm my Small cam 350 cummins with no silicone air clean hoses makes almost 100 plus psi its still there oooooooooppppppppppssssssss with its 500 plus hp to the ground and fuel pressure of 300 plus go figure ?????????

 

[Niki]

Gee only 30 pounds psi hmm my Small cam 350 cummins with no silicone air clean hoses makes almost 100 plus psi its still there oooooooooppppppppppssssssss with its 500 plus hp to the ground and fuel pressure of 300 plus go figure ?????????

You have fernco hubless rubber connectors from the hardware store on that truck and they're holding 100 psi? Silicone, rubber, or whatever, if you look at a side view of a radiator hose or an intercooler coupling, you can see the fabric reinforcing, radiator and heater hoses, rubber fuel line etc have at least one layer, intercooler couplers have 3 or 4. The plumbing couplers have none, because they're designed for drain, waste and vent, no pressure. OEM intercooler couplers are at least reinforced rubber. Silicone couplers, hump hoses, piping are all dirt cheap on ebay and its good stuff. I've seen what some vendors want for hump hoses and silicone hoses.

 

[DVolk]

7.3L Powerstroke Intercooler in 91.5 Question

On my Pterbilt i have the standard air filter tubeing and rubber hose set up not the hardware stuff .



but the rubber silicone composit what ever that those are made of is a heck of alot thicker than any of the oem stuff any how plus i have schedule 80

industral pvc inside of that the only place were its not ran is the elbow

on my burb project OEM stuff is not even close to to the stuff i have

a rubber breaks down in sewer use so its a type of synthetic stuff im shure