Hi, can someone tell me what exactly is required for the swap? I'm very confused, have heard from different people I need the swap the fan, its impossible, the ac condenser is different, etc. I have the crossflow rad and the intercooler + all the plumbing for it, and the welding skills to mount it in if required. It's an early 91 with the new style grill. Thanks!

 

The intercooled and NON I/Ced clutch fans and the fan hub is different.
So is:
The rad., fan shroud, and the upper radiator hose outlet off the block, are different as well.
The turbo, 90* elbow and the intake horn is also different.

 

Just had the rad and intercooler tested... The rad is fine but the intercooler leaks all over. What would be a better intercooler to get? I'm thinking off of a 7.3 or a 2nd gen?

 

Read through the Sticky.
There is a great write up on using a 2nd gen I/C with your NON I/Ced radiator.
That swap work best with the '91.0s.
I did that swap on my '85 crew cab with a 91.0 core support and a bunch of 2nd gen parts.

 

I'm going to leave the intercooler till after harvest, probably will go with a 2nd gen intercooler. Going to be hauling a 165 gallon fuel tank, DEF barrel, a few gas jugs daily. Last spring it would start running on the hot side with 30 canola bags and a smaller fuel tank. Just to confirm, I need:

Fan Clutch
Fan Hub
Fan Shroud
Upper radiator hose(Might as well replace all the hoses while i've got it apart)
The larger radiator

I want to get all the parts right so I don't have the truck parked for too long.

 

Depends how you do it.
With the 2nd gen intercooler swap you can re-use a lot of your stock NON I/Ced parts.