Intercooling a non-intercooled truck

[jdurham]

Do any of you guys have a photo of an intercooled (91. 5-93) radiator core support? I think I found one, but I want to make sure.



Thanks,

Jim

 

[M'staedt]

I did have a picture, which I now can't find. The giveaway is the two large oval holes on either side of the rad opening. The intercooler tubes pass through those holes.

 

[jdurham]

M'staedt,



Thanks for the info! That is exactly what this one had, so I'm getting it. I figured it was right, but I hadn't seen one before.



Jim

 

[bgilbert]

intercooling a non-intercooled

Ok, how do I get started intercooling a non-intercooled truck? Junk yard, different radiator? Maybe I need to do some homework and find out how the intercooler works. .

 

[dusthomps]

bgilbert...



You really have two options. Banks makes an intercooler setup for the non-intercooled trucks. I priced this maybe 6 months ago and it was around $950. The other option is to find a truck that was intercooled. You'd need to get the radiator core support, radiator, intercooler, plumbing from turbo to intercooler/intercooler to intake, intake horn, and the grille assembly (89-90 trucks). If I'm missing anything, someone will chime in.

 

[midwestdually]

what kinda prices can one expect to pay at a junkyard for these parts???on average.







anyone else out there provide an intercooling kit??

 

[BushWakr - RIP]

There really is a big difference between stock and aftermarket intercoolers.

To buy a 'stock' intercooler from a dealer up here it's about $900 Canadian.

There are very few 'used' one's that do not leak or will leak soon.

Banks has a good aftermarket, but pretty pricey... again it's a lot better though.

BD has one, I think, however the one thing I'm not sure about is if they sell the Banks kit or if it's a BD version.



Other than that, I don't know what to suggest.



Bob.

 

[dshockley]

I used the banks kit. I got it on sale for $800 straight from banks. I was very please with the kit though I wound up replacing the hoses, clamps and reworking the pass. side duct. All-in-all I am very happy with it.



Dan

 

[midwestdually]

dshockley... .



i was wondering if the kit that you purchased was the power pack or just the intercooler and hardware???



also... were/how did you get the guage pod ??? i really like that setup!!

 

[Gary - K7GLD]

I bought and installed the Banks Power Pack setup on my early '91 non-intercooled Ram 250 - it was the intercooler and exhaust system kit - no point in the turbo part of the Banks kit, since early '91's had a turbo that already put out 20 psi at full boost...



The kit went on as easy as could be expected, and worked as advertised - I was VERY happy with it - no problems of any kind!



With that kit, a Power Shot 2000 propane kit and injector pump tweaks, that truck would stay with ANY of the newer trucks, Fords, GM, etc. , pulling in the hills!

 

[dshockley]

midwestdually



I only purchased the intercooler. I wanted to customize the rest of the power mods and didn't feel that banks provided enough bang for the buck.



If you search the archives, you will see an extensive discussion of how I MADE the gauge consol. I laid it up in fiberglass and then covered it in headliner material. I would be happy to share more, but check out the archive first.



Dan

 

[midwestdually]

was wondering if a 93 radiator and intercooler will fit on a 90??

 

[jdurham]

midwestdually,



I am doing EXACTLY what you are talking about. I have a 90, and the donor truck is a 93. Core support, intercooler, and all piping all the way up to the motor and turbo are required for it to be a bolt on job. I haven't actually done it yet, so I think there is more, like you need a different water neck to do the swap because of the different location of the radiator inlet. Sorry I can't be of more help, but I'll be doing the swap soon, and then I'll know more about it than I ever wanted to...





Jim

 

[Hutchew]

A Bonus..............

is that the radiator in a 91. 5-93 truck is a better design, cross-flow instead of downflow (?).

 

[midwestdually]

jdurham



what did you pay for the intercooler in the junk yard if you could be so kind as to tell me?

 

[jdurham]

midwestdually,



Can't help you there, as I bought an entire wrecked truck including cab, motor, trans, wiring harness, and interior. All it didn't have was a rear end, bed, or front sheetmetal.



Sorry.



Jim

 

[ToolManTimTaylor]

His name Matt S , https://www.turbodieselregister.com/forums/attachment.php?s=&postid=205494

I remember seeing the intercooler and man what a sweet deal! Banks intercooler install was straightforward and a snap if I remember (Man that is an OLD pic)

 

[midwestdually]

whats the deal with the HOoters girls?

 

[Scot]

Check with your radiator shop and price a new intercooler. I can buy a new 2nd gen cooler for $374 across the counter locally as of 6 months ago. That is walk in off the street price.

 

[midwestdually]

a second generation cooler will work in these trucks also???