The older Cummins (5.9 12 valve) are very durable motors that seem pretty easy to work on. The rest of the truck is the problem. The auto trans in the Dodges makes the E4OD look like a paragon of reliability. And you'd be seen driving a Dodge, which makes it a non-starter for me...
Get an IDI, and if it doesn't have a turbo, add one. Most turbos will last several hundred thousand miles, it seems most guys go through pumps and injectors a few times before any turbo-related issues pop up. More power, much greater drivability, and equal or better fuel economy are the benefits. My IDIT feels pretty similar to the 7.3 PSD I had (but quieter), a NA 6.9/7.3 feels like a motor from a distant, bygone era. Of course, not any more so than a stock 1st gen Cummins...

 

Are blown head gaskets valid concerns? And can the turbo be added and removed at will or are there timing and tuning differences?

 

a stock non turbo 7.3 IDI came from the factory with 25-30 more HP thana stock first gen 5.9 turbocharged cummins.
i am not a fan of the little cummins engines, as most people here know.
when new my 7.3 outpulled every cummins it came up against, even though the owners called it a piece of junk.
my piece of junk is still running strong after all those first cummins have been melted down for scrap metal, and the second and some of the third cummins have been melted down too.
adding a turbo to a 7.3 is very easy. tuning is nothing more that turning up the fuel a bit, and setting the timing.
the timing set is about the same for turbo or non turbo, it will just run a little better fine tuned.
blown head gaskets are only a concern at high boost levels.
and as far as adding and removing a turbo, i see no reason to remove it once installed. if my turbo ever needs work, i will just lay the truck up until it is repaired.

 

this engine (and it's turbo if equipped) are not worth the concerns or worries you have with them.your 6.oh no experiences/concerns need not apply with this engine.it's clearly dampened your diesel experience.
our main concerns here are with the rest of the truck due to high miles and age.not their engines.
if you can find an old idi truck still worthy of the parts,then grab it and toss the parts at it to keep the truck from deteriorating around the engine.this ain't no 6.oh no.you just change the oil and drive it.

 

I have only really heard of one person have head gasket issues,40psi will do that, one user said it best...cant remember who...idi's are as mechanically complex as a hammer...this is true, the only reason they wont run is no fuel, zero elwctronic, and this may seem funny to you but i live just outside Columbus in and still you could not give me a cummapart. There are those that swear by them, IH DT360 will leave a cummins crying...its all prefrence really, i have had all of the big 3, and you see where i am now, I'll bet most on here are the same way

 

Really, the difference between 'turbo' and 'no turbo' on an IDI is:
1. Turbo unit connected to exhaust manifold and intake manifold
2. IP maximum fuel increased due to the turbo being able to burn it all.
3. (optimally) IP timing retarded slightly to improve turbo spooling and power.

A 'turbo-tuned' engine /without/ a turbo will work fine, but unless you reverse the IP fuel adjustment, you have to be careful with your throttle pedal -- floor it and you'll /pour/ black smoke due to not having enough air to burn the fuel.

Any timing adjustment differences are miniscule and will not massively affect drivability. If my turbo failed, I'd not hesitate to pull it off and drive the vehicle... though I would miss it greatly: I'm at 2000ft, so I'm already losing 8% power right off the top of the NA engine which is already somewhat anemic.

Do note that in 1993-1994 there was a 'factory turbo' 7.3 IDI which was /slightly/ different internally - it had some minor changes to the pistons, connecting rods and block, though these changes don't seem to have made any difference in longevity with a turbo -- the "NA" IDI blocks work just fine with an aftermarket turbo kit from Banks, ATS, or Hypermax.

As far as blowing head gaskets go, 15 PSI of boost seems to be the maximum safe level long-term with stock gaskets and bolts. The Banks kit I have is limited to around 12 PSI via it's wastegate. It's only when you have a custom turbo kit or want to put in massive boost that it becomes a problem; 20-35 PSI requires studs; beyond that, you are going to be shaving the pistons and such.

 

Alright thanks everyone! So far I am definitely looking for an IDI that I will add a turbo too later on, does the 5 speed have a big fuel milage advantage over the 4 speed, or is the difference negligable?

 

The five speed will help, but even the 4 speed will do decently. My '84 was a C6 auto which gives you a direct drive final gear like the 4 speed will and it gave me a faithful 15mpg which I always felt was good for a 3/4 super cab tank.
Some guys with the proper gearing and tuning (and driving) do report high teens.

I think the turbo vs head gasket concern is on the 6.9 as it has the smaller head bolts, but again it's just a debate, no conclusive answer as far as I know.

 

Didn't racin' try to use the 7.3 studs on the 6.9 by drilling and tappin the 6.9 block?

 

The 7.3 idi trucks are awesome.
Run evans waterless coolant.

I once drove one with a 4 speed, and it wasn't what I would want, the 5 speeds are really nice.
A well running idi will purrrr away just as nice as any other diesel, a little loud, but once you get driving it is very nice.

I might be wrong, but I think the idi engines are way better on fuel driving in town and low speeds than newer motors.

 

Well, lots of good comments, like most of these guys, I've had a 6.9 non turbo with a C6, not a rocket but rock solid and steady pull. I've had two 6.2's, one with a 700R4 and one with a Turbo 400. Both of my 6.2's ran and ran and ran. 200,000 easy on each before I sold them and they were still going strong when I sold them. I could get 20-22 mpg all day long with the 700R4 tranny. Now I have a 1993 ext. cab 4x4, five speed non turbo that I installed a brand new Banks Sidewinder. This truck has been well cared for, has 310,000 miles, it's tight powerful gets 20 mpg and I think the only way it could be better is if it were a 4 door. Bottom line, my opinion, 6.2's recreational diesel motors, fine for light duty long mileage. 6.9/7.3's real truck motors not quite as lively but all around better truck and working motors.

V-465