Several months ago, I purchased a 93 W250 LE automatic.
Always wanted a diesel, and this truck has been a disappointment. No power, so I pulled the intercooler and benched tested it. It has hundreds of pinholes in it so is useless. Chrysler doesn't make them any more, and Gale Banks wants my first born for a new one. How much power difference will there be if I find an original intercooler to replace this one? How much difference is there in power between stock and a Gale banks?
To make matters worse, I find water in the wall at my feet. I have read on these FAQ's that its a cracked cowling fix. I can see a moon shaped opening at the top of the cowling on both sides of the truck. Does this mean that I have to dismantle half the truck to fix proper?
I could go on, but I don't want to overwelm anyone on my first thread. I should have found your website before I bought the truck.

 

On a stock truck the Banks intercooler isn't worth the money. You need more fuel to make more power, more air won't do that for you.

Intercoolers do not need to be 100% leak free. Cummins allows a max pressure loss of 7 psi from 30 psi in 15 seconds. You intercooler may be "acceptable".

These trucks are not powerhouses stock, but swap turbine housings and fiddle with the pump a bit and they will pull very well.

Never dealt with the cowl cracks myself, but yes, I'd imagine the only way to fix it would be to take the fenders off..

 

I have the same truck stanard and ext. cab though 232k its had its prob. but its been an extremely reliable rig.dont get down on it right off the bat take 1 problem at a time do it right and dont try to cut coners I would keep it stock to avoid adding to the confusion but that is strickly up to you and your wallet.by the way I have been a maple leaf fan for 44 years so as you can see I like to stick with things.Go Leafs Go

 

if you need a stock intercooler you should look at this place:
http://secure2.cybrtyme.com/store_cg...l?id=13&step=2
I havent priced out intercoolers so i dunno how reasonable these prices are.

 

That's a steal compared to Bank$! Great find ares!

 

Ditto what he said.

Stock mine was a DOG. I replaced the turbo housing and turned up the pump. I also put on a 3" exhaust. What a difference. My cab leaks and creaks also. I will fix it someday.
Dean

 

It might be cowl cracks, but the first thing I would check is the vent on the side by your feet.

 

My truck was a absolute pig when new. I finally said the hell with it and removed the crimp on the fuel screw and turned it all the way in. About a 100 horse gain and I was all smiles. Needless to say over a million miles later Im still driving it.

 

Well i lucked out got a nice truck that runs like a top,,but the others are right stock they aint power houses,but with a little time and effort they can be,just fix things right and dont lose paitients the milage alone is worth it,

 

my 93 W250 was pretty underwhelming in stock trim. after a smaller turbine housing, a few turns on the fuel screw and a DTT tranny, she's a hard pulling bad-@$$ truck.

FWIW, while she didn't have much poop before, she hauled and towed pretty good.


jeremiah

 

What about a 2nd gen inter-cooler? I've seen a post somewhere that it will work mounted upside-down. I think there is someone here who is even running a powerstroke inter-cooler (maybe it was Old Smokey ????).

 

I think Okie posted pics of a cowel fix. To get by awhile and see if the leak stops, sand any rust off and cover with some tar or under coating. The fix is suppose to beef up the corners to prevent the split from growing. I have the cracks, but they don't seem to be going anywhere.

 

I have a stock 250 with an intercooler on it, and it has good power for pulling and hauling. I have worked it like a rented mule and it has never disappointed in the power department. If you're looking for a truck to race guys with or something, then you're going to have to open up the wallet and modify it. They just aren't made to do that. You can do the fuel screw thing for some extra bang though, as suggested above. It may be that your engine is worn, or not running well as well.

The cowl fix is a p.i.t.a. if you want to do it properly, but there are quick fixes to tide you over until you're ready to do it. Gooping with silicone/tar etc.

I hope you're able to get her running to your liking, and that your next posting is that your truck kicks a*s!. Good luck with it!

 

As far as the leaking problem goes I woul take a look at the vent before tackling the cowl. The vent fix is fairly simple. Take off the kick panel on the drivers side and seal up the vent hole. One other possiblility for the leak is the windshield.

 

hey guy...don't even begin to throw the towel in yet! I've had my 93'd250 clubcab for 17 months now and 186k miles to date she's well worth it in fuel and reliability alone! I haven't touched anything...yet. She's been totally unmolested. However, don't get me wrong...I have about $2500 bucks thats gonna be going into her next month when i take a mini vacation(to work on her! hehe!)
yeah stock they're a little slow, but deal! once the turbo kicks in you're passin' every other freak on the road in their gassers! nothing like a diesel...absolutely nothing! And, if wasn't for this website here, I would of ended up with a power(less)stroke or a Dura(crap)max! Thank GOD for Cummins and this site!!!