AudioFreak:
The issue of DC resistance in the inductor is something that might affect things. On the one hand, all other things being equal, a higher quality inductor will have less DC resistance than a cheaper one.
On the other hand, air core inductors are likely to be superior to iron core ones. However, at lower crossovers, air core inductors are going to have higher DC resistance.
In instances where his new inductors have less DC resistance than his stock ones, he can always add resistance in series to make up for it. If he switches to air cores inductors with slightly higher DC resistance, there is not much he can do if it affects the sound for the worse except to put the stock unit back in.
We don't really know that DCM has programmed in the DC values of it's components when making the crossovers either.
One thing is for sure-if he can replace an electrolytic capacitor with a poly capacitor, there is no way he can go wrong!
About the only thing I can suggest is that if he gets his crossover components from a high quality supplier such as Madisound,
www.madisound.com , then he should go for the air cores if it is within his budget. Madisound is unlikely to stock something that they have reason to believe will make the crossover sound worse. Iron cores do introduce distortion, but they are cheaper per henry than air cores.
Incidentally, although I have had experience designing crossovers from scratch, I have not replaced the crossovers of existing units before. I am just applying some "rules of thumb" to the issue here. Anyone who has done modifications of this type, feel free to jump right in.