gotta I’ve got a ford intercooler for mine that’s today’s project didn’t know if the 2nd gen had an advantage

 

cabtruck,
On the Non Intercooled '91.0 trucks the 2nd gen intercooler is a great option.
A tape measure, hole saw, grinder, a cut off wheel or saw-z-all and you have a pretty easy project with simple hand tools. I have the welder in the shop so I can use that where I feel the need, but it is not needed depending on how you want to do it.

I have heard the PS intercooler works well on the '92-'93 trucks.

The real advantage for me is having the parts here to do the swap on hand already.

 

...

 

I got the core support hole-sawed out last night before dinner. I am ready to grind the holes smooth, dab a little primer / paint on the wound and start test fitting the intercooler. Then I will modify and locate the lower mounts and weld them up.

 

I got the intercooler where I wanted last night. I got the holes in the core support ground smooth with no sharp edges and the 2nd gen intercooler mounts welded in and painted.
I have to get the top bolts for I/C in place that figure out how much of the secondary hood latch I will need to trim up next.

Then it is time to swap out the turbo for that HX-35 and sort out the intercooler tubes.
Good times in the shop after the sun goes down at 4:15.

 

I got the intercooler trimmed and ground down for a cleaner fit behind the grille. It has a few bumps on its for mounting the A/C brackets and such cast into the intercooler. They protrude on the front side of it and they get in the way of the back of the grille..
Right now I am pressure testing The I/C the nice and easy way I like.
The intercooler is currently full of water and sitting on my shop floor supported by a tire on its front.
I have about 3 gallons of water in the intercooler and I see no spotting under it.
I will check again after dinner.
If there are no leaks I am thinking I am good to go.

 

The intercooler is fitting nicely in the core support now
I have the HX-35W off a '96 12V ready to install. I drilled and tapped a boost elbow into the cold side of the turbo for the waste gate. Once the turbo is on I can see what I need to do for intercooler tubes.
Charlotte helped me remove the A/C pump, bracket and lines tonight. At that point I saw some orange gasket maker on the oil filter housing which was always a little oily. It appears, now there is no turbo and A/C stuff in the way, that the small oil drops Poncho would leave on the ground where coming from an oil filter housing leak. It would then leak down the block, engine crossmember, ETC keeping everything well oil undercoated.
I put a 10 MM wrench on the filter housing bolts and they where ALL at least a little loose. I will be pulling the oil filter housing and installing new gaskets here next. I have the gaskets on the shelf, so at least I don't have to wait for them to show up.
It seems like I just keep taking parts off the truck that was running fine a few weeks ago. The classic, "while I am here" scenario is taking hold. The access to that oil filter housing is pretty good right now so it is the time to fix it.

Maybe I can fill the radiator up with 100% antifreeze when I am done. I know that will make Mark happy.

 

My daughter and I took the afternoon off and took some turns on the MT.. The skiing, snowboarding and fresh air was fun for us. We then made some homemade Christmas presents this evening.
I will get back on Poncho tomorrow night after I get a clean 5 gallon pail for the anti-freeze, so I can tear into it some more.

Thanks nonrev, I was starting to think I was just typing this out for me.

 

Don't get lonely mr. foster... I'm subscribed to this thread and I read just about everything you and a few others post

Always very helpful

 

I had the same thing on the 93 motor in Patches....all the bolts on the oil cooler were loose, some only finger tight!

 

That "while I'm here" mentality will get you every time. That's why I'm at where I'm at on my pile.

 

I wish I read this a few months back.

Had the truck apart, and could have easily checked the torque on those bolts while I had it apart.

Oh well. Another day, so it is..

 

Oliver, Are you changing the rad out for a Cross Flow due to adding the intercooler?

 

Nope.
When using a 2nd gen intercooler on a '91.0 you can keep the stock radiator, fan shroud, fan hub, clutch fan and upper rad. neck of a non intercooled 12V.
With a manual transmission the smaller, earlier radiators give me all the cooling I need.

If I used a '91.5-'93 intercooler I would have to change all those things along with the core support, intercooler, intake horn, boots and tubes to get it to all look stock and work right.

I am basically following the 2nd gen intercooler swap as specified in the sticky with a few of my own mods, so it works better for what I want.

 

I got the radiator drained last night, so I can pull the oil filter housing neatly without spilling "alien blood" everywhere. That was about all I got done before dinner.