Coverting an '89 to intercooled
 

Hey guys, I have looked at numerous old threads and stickies on the conversion. I have been restoring my '89 W250 from the ground up for the last 4 years, just takes time and money. Currently I have a complete 93 intercooler and tubes laying around. I have a mint '93 gasser rad support and grill, yes I will have to cut it up. But my real question is will I have to convert everything over to a cross flow radiator due to running the 727 tranny? Or can I stick with the original rad. The conversions I have read most are running a 5 speed. If I go crossflow I will have to change out the fan hub, thermostat housing, and fan pulley correct? Wanna do this once and done. Thanks.

Add clutch fan and fan shroud to your list if you want to go that route.

You will need the turbo with the 90* elbow and intake horn as well to round out the list.

I don't know much about how much cooling an auto needs, as I don't run them.
I would guess how much power you are making and how you use it in the end makes a big difference.

I have a HX35 to put on the truck. And I have a fan and clutch off a 97. Guess I'll do some digging on parts. Before I tore the truck down I could hit some high EGTS pulling hills, and figured while I'm building this truck It would be in best interest to put an intercooler in it,

For the amount of custom work you are looking at doing I would look into using the much bigger 2nd gen intercooler, boots, tubes and intake horn.
I am doing that swap for the third time now on my '78 Ramcharger. My '85 crew cab and my 91.0 W-250 where converted from NON intercooled to intercooled using a HX-35 and 2nd gen intercoolers and parts.

Check the write up in the sticky for some pictures and details. I followed the sticky write up for the most part.

Thank you Oliver. I might hit you up for some parts if you still have stuff on the shelf.

It seems like I put Cummins stuff on the shop shelf faster than I take it off - even while building / rebuilding 2, 1st gens and fixing up a '98 quad cab 12V 5 SPD from TX currently.
Just let me know what you may need. If I have room I could always bring it down to Carlisle.

I agree with Oliver....converting to a complete IC style system is more work then it's worth IMO. If you are concerned about cooling, engine temp wise, then have your Non-IC rad re-cored, or have an Aluminum unit fabbed up. There is also an after market kit to add an IC to a NON-IC truck from CRX racing?? The have them for sale on E-bay. I have come across a couple people who have used the kit and they claim it was a decent set-up.