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Intercoolers

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NV4500 speed sensor

  • MikeN
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Starter/Bellhousing Location

  • Slaughter
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britannic

My military Chevy M1028 K30, doesn't have A/C, so there's nice spot to mount the intercooler in front of the radiator. I'll still need to modify the core support pillars though. The dimensions available are 31" wide, 17" and around 3" thick.



A Ford Powerstroke I/C isn't too far off those measurements. How about the Ram's I/C? Suggestions on which I/C to use will be most welcome. TIA :)
 
Did you fit this into a Chevy? I'm looking for the most efficient way to mod the core support without compromising the crash strength. I thinking about welding in steel 2x2 box section if I sawzall the main core supports to accomodate the powerjoke intercooler.
 
Intercooler

I used the Power Stroke cooler, works well. I just had to notch clearance for the inlet and out let tube for the sides. I then built a tray with foam for it to sit on. On the top I modifed the intercooler mounts and secured them to the front with two bolts.





I can take some pics, I have the front of the truck apart right now to install AC.





Malcolm
 
Anyone ever used a GM D-Max intercooler? I have one and am thinking of using it for my cummins swap into my 1989 GMC. Height and width wise it fits perfect with my huge rad that I have now but I am going to have to modify the core support quite a bit to make it fit. Does anyone have flow stats on the GM/Ford and Dodge intercoolers??? And also inlet diameters on all 3??? I would like to use my D-max one because my rad is HUGE and it fits perfectly but if I have to get a ford or dodge I guess I am going to have to.





Thanks... Ryan
 
It will flow just fine. The stock Dmax puts out around 24-26psi and bombed, they pull mid 30's boost. The engine is a 6. 6L with wide open fuel around 140mm3/stroke x 8, over double the amount a stock 1994 160HP 6BT auto injects (76mm3/stroke x 6). For actual CFM and BTU rejection you may want to check this forum out: Duramax Discussion
 
Last edited by a moderator:
Originally posted by britannic

Did you fit this into a Chevy? I'm looking for the most efficient way to mod the core support without compromising the crash strength. I thinking about welding in steel 2x2 box section if I sawzall the main core supports to accomodate the powerjoke intercooler.
Click to expand...



If I can get my scanner to work I'll post some pics of how well a M1009 holds up to having the front end hit at 75 MPH. I never was a Chevy guy but after that lady hit me I was impressed:cool: Ripped the side right off her Dodge and she got all messed up. Stupid ^%^(%( shouldn't have been playing with the radio and stopped at that red light:mad: :mad: :mad: :mad:
 
inner-cooler

Thanks Neil, I used a 30* 3" pipe for the intercooler on the "cold" side and a straight 3" on the Hot side. It now has a different hot pipe with the twin set up.





Malcolm
 
Britannic,

I used a 97 dodge intercooler on my 85 suburban conversion and all that it required was cutting off the intercooler inlets and swapping(rewelding) side to side. Cleared the main supports on the radiator support perfectly. I will try to post some pictures of my conversion now that I have a new computor that I can hook up my camera to.
 
Thanks dcamilleri. Which NP205 are you using with that NV4500?



Originally posted by dcamilleri

Britannic,

I used a 97 dodge intercooler on my 85 suburban conversion and all that it required was cutting off the intercooler inlets and swapping(rewelding) side to side. Cleared the main supports on the radiator support perfectly. I will try to post some pictures of my conversion now that I have a new computor that I can hook up my camera to.
Click to expand...
 
I used a late model 205 gm case (round bolt pattern) and originally used 32 spline turbo 400 input gear, it bolted right up to the back of gm nvg 4500 with only some clearancing for the shift rail. Problem was I ate the splines off, twice in 15,000 miles. I am now running a full splined dodge shaft with the male dodge input gear and coupler (1 1/2 29 spline) I think part of the problem with the gm shaft is that it is long and doesn't splash much oil on the splines and they erode. I hope it is fixed now.
 
I'm wondering if the Dodge NP205 with the circle bolt pattern would fit, it has the passenger side drop as well.



BTW, I read on these boards somewhere that the fix for lubing the splines was to remove the rear NV4500 oil seal and allow the gear lube to fill the void with the transfer case - same as the auto transmissions do. I've not confirmed if that's the right thing to do, but it seems to make sense.





Originally posted by dcamilleri

I used a late model 205 gm case (round bolt pattern) and originally used 32 spline turbo 400 input gear, it bolted right up to the back of gm nvg 4500 with only some clearancing for the shift rail. Problem was I ate the splines off, twice in 15,000 miles. I am now running a full splined dodge shaft with the male dodge input gear and coupler (1 1/2 29 spline) I think part of the problem with the gm shaft is that it is long and doesn't splash much oil on the splines and they erode. I hope it is fixed now.
Click to expand...
 
Dodge transfer case uses same bolt circle but the indexing is different. If you use a gm transmission(nvg 4500) just use the dodge tail housing. My swap would have been a lot easier if I could have found a Dodge transfer case to start with. Also watch out for transfer cases from an automatic since they use a 23 spline shaft, you would have to change the input shaft and coupler.
 
re: splines

my chevy tail housing does not have a provision for a seal in it, but the housing is 2+ inches longer than the Dodge tail housing. I was also overfilling with an extra quart of oil and that didn't seem to help either. I still think that the main problem was that the splines were not getting splash lubed from 5th gear since they were further away. BTW when I originally assembled my trans to transfer case I left the splines dry. I failed the splines within 4000 miles. 2nd time I greased the heck out of the splines and they lasted 15,000 miles. If I had my choice I would seal both sides of the shaft and then fill the cavity with same type lube as transmission and I am confident the problem would go away.
 
Well, sadly I didn't realize that Ford changed their dimensions (or they may not have - need advice here please) for the 2003 PSD intecooler (18"x30"x2"), so the one I got isn't going to work with the stock radiator and core supports (unless I completely remove them) and change to a narrower radiator.



My truck was originally a 6. 2L diesel with the big radiator (40. 5"x21"x3. 5" overall). . I notice that the Dodge '99 intercooler is 46" x 15 1/2" x 2 1/4" with 3 1/2 inlet and outlets, so that may be more feasible.



If anyone has the dimensions of the earlier Ford PSD intercoolers and which years they were fitted, I would greatly appreciate it.
 
Originally posted by britannic

Well, sadly I didn't realize that Ford changed their dimensions (or they may not have - need advice here please) for the 2003 PSD intecooler (18"x30"x2"), so the one I got isn't going to work with the stock radiator and core supports (unless I completely remove them) and change to a narrower radiator.



My truck was originally a 6. 2L diesel with the big radiator (40. 5"x21"x3. 5" overall). . I notice that the Dodge '99 intercooler is 46" x 15 1/2" x 2 1/4" with 3 1/2 inlet and outlets, so that may be more feasible.



If anyone has the dimensions of the earlier Ford PSD intercoolers and which years they were fitted, I would greatly appreciate it.
Click to expand...



I'm going to use the dodge 98-2002 intercooler with my swap into the 86 chevy and it fits ok turned upside down and using the air cleaner duct holes in the radiator bulkhead to plumb it up.



William... .
 
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Issue 128 – Digital Version
Digital Magazines
FREE!
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Renew
Subscribe
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Back Issues
Subscription Status
Address Change Form
Buyer's Guides
Ram Diagnostic Trouble Codes
The Perfect Collection
The Perfect Collection Vol. II
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Dodge/Cummins Historical Overview
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What Makes Us Tick?
Product Showcase
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