1990 Ford E350 4x4 w/R&D 7.3 IDI Build

VANMAN

Observer
Hello All,

I Previously posted my mockup for putting an Intercooler in my van (Some folks have said there is no room in 1975-1991 ford vans for an intercooler). Anything can be done if you want to spend $/Time. I wanted to mock this up before my new 7.3 was put in so it would be less aggravation when putting in the new engine.

I now have the new engine in the van. To say it is an improvement is an understatement. The previous engine was a stock 1990 7.3 IDI with a Banks Sidewinder turbo I installed about 20 years ago. The banks was an improvement. But as anyone knows these 7.3 IDI's stock while great motors were a little underpowered especially when pulling up long grades. I figure with the Banks Turbo I was probably putting about 190HP to the rear wheels maybe a little more or less and maybe 250HP Net @ 2800 RPM or so (winding it out to get up hills)

Kudo's to Justin @ R&D IDI. The new 7.3 IDI is a turbo block, Girdle on the lower end,Forged Rods, Ceramic coated pistons, different cam,ARP studs bottom and top, much better Turbo, Injection pump flows way more than stock. I did not want a race truck just a bit more performance. Goal was 300HP 700TQ to rear wheels. We think net its probably 380/800. This has not been on a dyno. I probably didn't need girdle or forged rods but wanted them for insurance.

Completely different engine, much smoother, pulls great. Before with old engine I either had to wind it out in a lower gear or try to keep RPMs up to hold 65-70 up big grades, and I was not doing a whole lot of passing. Now, no problem partial throttle right up whatever speed I want for road and conditions. Before 10-13 psi boost max, now 15-20 psi partial throttle, 25-30 psi max. It is a pleasure to drive. Much less shifting required.
 

VANMAN

Observer
As you can see from previous pic I did have to move the grill out a couple of inches, which wasn't too hard. Did it during crazy Covid spring when nobody was getting out much. Aluminum cut and bent to fit around grill.

For the observant you will notice no air-conditioning condenser behind intercooler. A new one is going in behind intercooler and will fit, just haven't done it yet.
 

VANMAN

Observer
ZF 5 Speed with Single Mass Flywheel, Transfer case, DNE2 Overdrive for gear splitting and Double overdrive.

Incidentally, DNE2 has electric motor removed and is manual operated. Putting in shift mechanism from JB next week. Currently have to reach under van to shift.

On another note, I have 4:10 ratio in axles. With overdrive engaged it effectively changes ratio to about 3:28. New engine will pull up hill MUCH better with overdrive engaged than old engine with 4:10's.
rR4WvzZTTGi+TmQbIoqi1g.jpg
 

VANMAN

Observer
Update on engine...This engine is great....much smoother and more powerful than it was stock....The Cam the Justin@R&D IDI uses is awesome...it pulls from about 1200-1400 great....so much so that I don't have to shift gears as much....Case in point....driving thru Montana and Idaho....I would be in double overdrive at 65-70...have to slow down for towns. say 35-40 MPH and never shift...just gradually roll on throttle from 1200 rpm...I couldn't due that with stock motor..

I also worked out the cable and shifter on the US gear overdrive....used at ratchet style emergency brake shifter....no electric motor to relay on All Manual..shifts smoother too.

In double overdrive @70 MPH Im turning about 1850 RPM
 

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