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Are there any other differences between the 89-91.5 models and the 91.5-93 models?

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92 D250 Battery specification.

Setting port closure

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Yes again.....



There are a number of differences and some of those are as follows;

Lets reference the earlier trucks as "early models" and "later models for ease of identification...



1)The early trucks had no intercooler which is used to cool the boost air coming from the turbo and going to the intake plenum, were as the later models had an intercooler. (you can tell by looking to see if there is a large tube/piping connection that goes over the top of the head and connects to the intake manifold... if there is, it's a NON-INTERCOOLED truck.



2) The early trucks had different injection pump timing settings which ranged between 1. 35mm 1. 40mm spill port timing. The later models used 1. 25mm spill port setting.



3) There is some crossover here regarding turbo's exhaust housing component ... . from 89'-91. 5 they came with an 18. 5cm housing, then from 91. 5-92 they used a 21cm housing and finally during the 93 model year run they went back to the 18. 5cm exhaust housing.

**NOTE** the smaller the exhaust housing the quicker the turbo will spool up and start to produce boost. In addition the total boost will usually increase roughly 2-3 psi for each size DOWN you go in housing size.



Pastor Bob.
 
More differences

The older ones had 9mm injector tips, vs 7mm for the newer ones.

Air inlet to the turbo was 3" on the older ones; 4" in newer ones.

Head gasket is stronger in the newer ones; older ones are more inclined blow the headgasket when high temps or high boost is used too frequently; replace it with a new, updated version and, you're good to go.

Power Steering/ vacuum pumps are different. However, if you replace the entire unit from the drive gear back, it will fit, with some trimming of the throttle shaft bracket.

Radiators were smaller in the older ones.

Older autos had no OD; instead you had a choisce of 3. 54 or 3. 07 gears. The 3. 07 wont interchange with ANY other Dana 70 axle.



Daniel
 
'89 to '91. 5 W250 trucks came with a 6" frame rail, while the '92 to '93. 5 trucks came with an 8" frame rail.
 
Admittedly trivial, but the 93 has a larger ID air cleaner than the 92 for better flow (and more expensive filter). The fuel lines also have different connectors.
 
Water jacket aftercooler( commonly called an intercooler , an intercooler resides between a pair of twins) early first gen
Air-to-air aftercooler late first Gen
Heat load put directly into the engine cooling system from the WJAC.

Rear spring bushings
Energy suspension lists 2 bushings for the rear spring shackles on the first gen's 99.5 doesn't have either it has 5/8 Bolt. Book lists a 3/4 and 1/2 in option for the bolt. I don't know if I simply have an oddball or if there was a difference my date of manufacture is 91 June
 
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