Banks Intercooler installation

[DJP]

Has anyone installed one of these in a '89 or '90 with air conditioning? My stock grill almost kisses the fins on my A/C condensor radiator, there doesn't seem to be enough room for an intercooler to mount in front of it. I ordered the chrome tube grill from Banks, when I pulled it out of the box, one of the tubes pulled loose. Whoever did the welding on these, didn't use enough heat on all of the welds. I hope the same welder didn't build the intercooler too, or I'm in trouble! Anyway, I sent the grill back to Banks last Monday, haven't heard anything back from them yet. I'm thinking I may have to install the '91 - '93 model grill (like jsimpson) in order to have it all fit behind the grill without having to space it forward like a Powerstroke.

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89 D-250 LE 5 speed 3. 55 Limited slip, K&N, straight piped, Boost/Pyro. & 16cm2 215K and still going.

 

[Gary - K7GLD]

I installed the Banks intercooler on my early '91 - no problems at all - it WAS required to trim the grille inserts a small amount, but no big deal. A *bigger* problem when installing the Banks intercooler, is the additional heat and airflow restriction it places on a cooling system that is ALREADY substandard when the truck is pushed hard - either the radiator needs to be replaced with something larger, or else it needs modification to provide more efficiency. I have had a baffle installed in the top tank of my radiator to force coolent COMPLETELY across the full width of the radiator, instead of "short-cycling" directly from the upper to the lower inlet/outlet of the radiator - cheap, but effective! (like my old girlfriend... ).

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http://community. webshots.com/user/davison71 Early '91 250, 727 AT, 307 rear... Banks Stinger exhaust, intercooler... US Gear OD... MORE than a match for every new PS Ford encountered so far...

 

[DJP]

The early model '91 has a completely different grill than the '89-'90 model years. I know for a fact there is a lot more space between the grill and the A/C condensor on the later first generation model years. I also know that the intercooler will fit (with some extensive trimming) behind the '89-'90 grills if you don't have an A/C condensor between the intercooler and the radiator.

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89 D-250 LE 5 speed 3. 55 Limited slip, K&N, straight piped, Boost/Pyro. & 16cm2 215K and still going.

 

[wxman]

I installed a "Turbo Shop" (TTS) intercooler (not sure if they're even still in business) on my '89 in 1991. There was no room whatsoever for the intercooler with the stock grill. We removed the stock grill (as directed), installed the intercooler, and installed the replacement grill that came with the kit.

By the way, the TTS intercooler is still working fine after almost 10 years... never have had a problem with it.

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1989 D250, 727 auto trans, 16 cm^2 turbo housing, Banks Powerpack, Turbo Shop Intercooler

1998 VW Jetta TDI, Powershot 2000 Propane System

 

[Matt S]

I installed my intercooler in my 90 with A/C about 2 weeks ago. The grill can be shaved in order to put it back. I however am now in the market for a nice used grill as I don't have a very steady hand with a dremel! #ad
My next one will be done using a straight edge. The intercooler mounts in the same location as the trucks without A/C.

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90 W250, 5-speed, isspro gauges, 16 cm2, K&N, Borgeson shaft, JRE 3" exhaust, Banks Intercooler, Lucas injectors

 

[jsimpson]

After searching three years for a painted 91-93 grille, I went to a junk yard that handles non-factory replacement parts and got a new replacement grille WITHOUT the indentations for the D-O-D-G-E for less than a hundred bucks!

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http://coffeewithJesus. homestead.com/web1.html 89 1-ton, Amsoil System 3000 5-30,K&N air filter, cleaned-up exhaust, Dynomax straight-thru, rebuilt pump, thermostatically controlled twin 14" Permacool electric fans, intercooler), modified 518 OD transmission, Gear vendors OD controler, R-134 refrigernt, louvered front fenders, 93 aftermarket smoothie grille, new Dupont Chromacolor black, black-and-red rubber rubstrip, black headlights, powdercoated bumpers; 78 35'Avion, 93 Lance 900 slide in with generator and power jacks. To see my truck, Click on: <A HREF="http://albums.photopoint.com/j/AlbumIndex?u=1169022&a=10097213

Jesus" TARGET=_blank>http://albums.photopoint.com/j/AlbumIndex?u=1169022&a=10097213

Jesus</A> saves!

 

[DJP]

I finally got my cheap looking chrome plated cattle guard (grill) back from Banks customer service today. I sent it out on January 29th, and just got it back today. I don't know what took so long, but maybe it was shipped via yak. Now that I have all of the pices, I will attempt this intercooler installation project this weekend. Anything I should be aware of during the installation? The instructions look pretty much straight forward, but where do I get a 3" diameter hole saw?

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89 D-250 LE 5 speed 3. 55 Limited slip, K&N, Full Boar Muffler, 3" exhaust, Diesel Dynamics Stage 1 kit, Boost/Pyro. & 16cm2 215K miles.

 

[Matt S]

I used a bi-metal type from Home Depot. Just let the saw do the work and don't push too hard. My holes went really easy.

 

[Lil' Dog]

DJP
Big Don customized his 89 grill to cover the intercooler. He had some photos posted a while ago. Email him, he is always ready to help.
The stock grill needs a good deal of trimming but still looks stock. I can not speak from experience, just Big Dons photos.

Good Luck!!

J-eh

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Jason Hoffman
Lil' Mack - 89 D250LE 5 Spd 3. 54 LSD Reg Cab. K&N,"tweaked pump", BD Injectors, Banks Pyro/Boost, 3. 5" Exst tail section straight. E&M Custom seats. Bosch H4, PIAA 80W/80W HdLites. 100W Drv,55W Fogs.
237,500 miles (380,000 Kms) 7850 Hrs. Cummins Power Booster member.
The Original Turbo Diesel

Lil' Mack Pics 07-00

 

[DJP]

I already e-mailed Big Don for the photos of 'Ol Blue's modified grill. It looks like a tight fit, the lower bezel looks like it had to be bent or tweaked in order to fit the intercooler in behind it. From what I understand, 'Ol Blue does not have air, but Matt has mentioned the intercooler mounts in the same location with or without air. I'm going to get a hole saw at Home Depot, and do the install this weekend. Thanks for your help guys, especially Big Don for making this group purchse possible for all of us die hard first genners!

 

[DJP]

I completed the intercooler installation today, but I'm still working on the grill. I noticed I only get around 16 psi boost with the intercooler installed (I used to get 20-21 psi) on heavy uphill acceleration. Is this normal, or do I have a leak? All of my manifold connections are tight, and I replaced the upper and lower grid heater gasketts. If I got a leak, it seems the only possible place might be the intercooler.

 

[Matt S]

My boost dropped when I installed the intercooler also. I can't tell you how much because I also changed from the Power Wagon injectors to the Lucas injectors at the same time. I would recommend driving the truck and retightening them while the truck is hot. I've tightened mine twice. I am anxious to get some warm weather to see where I can adjust my fuel for best power/ least EGT problems.

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90 W250, 5-speed, isspro gauges, 16 cm2, K&N, Borgeson shaft, JRE 3" exhaust, Banks Intercooler, Lucas injectors

 

[Gary - K7GLD]

Banks advises 2-3 lbs loss of boost thru their intercooler, which is what mine dropped. More than makes up for it in reduced air temp and greater charge density.

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http://community. webshots.com/user/davison71 Early '91 250, 727 AT, 307 rear... Banks Stinger exhaust, intercooler... US Gear OD... MORE than a match for every new PS Ford encountered so far...

 

[Big Don]

DJP,

glad you finally got the grille taken care of. The boost drop will be normal with the intercooler, but not alot. Do as the others have suggested and check clamps for proper tightness. All you need now is a good turbine housing, a set of the 'Ol Blue Specials and a couple of Powerchokes so you can show them your tailights, if they can see them for the smoke.

later
Don