Top 5 Best 5.9 Cummins Intercooler Upgrade

Looking for the best intercooler upgrade options for your 5.9 Cummins? Well, we have got you covered with all sorts of questions you might want to know about it.

We will cover the perks, installation procedure, and reviews for different upgrade options along with the manufacturer’s recommendations so that you can choose the best 5.9 Cummins intercooler upgrade according to your requirements.

So, let’s begin the hunt for the best intercooler upgrade!

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5.9 Cummins Intercooler Upgrade

Image
Product
Best Overall
Banks 25980 Techni-Cooler Intercooler System For 2003-2005 Cummins 5.9 L
For Dodge 1994-2002
Mishimoto MMINT-RAM-94KSL Performance Intercooler Kit for Dodge Ram Cummins 5.9 1994-2002
Affordable Price
American Cooling Solutions 24432 Charge Air Cooler/Intercooler for Dodge Ram 2500, 3500 5.9L, 6.7L
1994-2002 Dodge Cummins Intercooler Boot Kit
Mishimoto MMINT-RAM-03KBK Performance Intercooler Kit For Dodge Ram Cummins 5.9 2003-2007

Our Overall #1 Rated Pick

Banks 25980 Techni-Cooler Intercooler System For 2003-2005 Cummins 5.9 L

Banks 25980 Techni-Cooler Intercooler System For 2003-2005 Cummins 5.9 L

Key Features:

  • Turbocharger intercooler
  • Minimal boost pressure loss
  • Increases air density and boosts air
  • Improve combustion

The banks engineering firm has invented this intercooler kit under a similar name which provides maximum reduction in boost air temp and higher continuous power by providing fuel economy.

Some major automakers like Buick, Chevrolet, Pontiac, and others heavily rely on the Banks capabilities and their productions. Their mechanical engineering department is enriched with great minds who work to design up-to-date high-performance equipment.

This turbocharger intercooler kit includes a high flow high ram intake manifold, and it has got a thick and rugged core with an all-aluminum end tank. This kit makes sure of excellent performance with outstanding durability and great compatibility. It ensures unparalleled services compared to any other intercooler kit.

Upon considering all these excellent features of the intercooler system, we have picked this one as the best Cummins intercooler upgrade option.

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5.9 Cummins Intercooler Upgrade Benefits

Intercooler’s had become a standard for 12v Cummins dating back from the year 1991. Though vehicles since then come with a preinstalled intercooler, it is better to have a custom intercooler to increase the overall performance.

Let’s have a look at the major benefits you can get by upgrading your 5.9 Cummins intercooler.

Improves Power and Wide Inlet – Outlet

Custom intercoolers are bigger than stock intercooler. These intercoolers include high flow boost tubes and a wide-open inlet and outlet which results in higher and continuous power.

Cooler EGTs and Fuel Economy

More power at EGT will result in better fuel economy. And since it will use low fuel, low temperatures will be produced by the engine which will lower the exhaust gas temperature. So, it has the potential to increases the cooling capacity and balances the fuel mix with more airflow and cool dense air.

More Combustion, Better Workability

Dense air has more oxygen and more oxygen leads to more combustion. With more combustion power, a custom 5.9 Cummins intercooler system increases engine efficiency. Cummins intercooler upgrade will prove beneficial for engines as a denser air charge will increase the workability of engines.

Superior Build Quality

The tubes and fins of custom intercoolers have a better build quality thus more durable. The tank is almost 50% thicker than the factory-installed intercooler. It reduces turbulence and helps to distribute airflow across the core.

Direct-Fit Kit

Mishimoto is a renowned intercooler producer and they make intercooler kits for 1994-2002 Dodge models. Mishimoto intercooler 5.9 Cummins is a great choice as Dodge Cummins intercooler. User can direct fit both 12v and 24v 1994-2002 Dodge 5.9 Cummins.

5.9 Cummins Intercooler Upgrade

Here we tried to sum a few upgrade options of 5.9 Cummins intercooler for you so that you can easily select one based on your requirements. We have highlighted the key benefits and features of some of the best intercoolers available for 5.9 Cummins.

The top best product [hide]

Banks 25980 Techni-Cooler Intercooler System For 2003-2005 Cummins 5.9 L


Banks 25980 Techni-Cooler Intercooler System For 2003-2005 Cummins 5.9 L
This turbocharger intercooler system is a high flow high ram intake manifold kit which increases boosted air density with amazing durability and performance.

This provides an ultimate reduction in air temperature and also supply minimal boost pressure. Its improved combustion and better engine efficiency deliver higher unceasing power.

Banks is a world-famous engineering firm that produces great kits for vehicles. Bank was founded in 1958 and they have more than 200 employees who continuously work hard to develop up-to-date kits to give vehicles robust performance.

So renowned car companies like Buick, Chevrolet, and others heavily rely on Banks and their engineering department. Their 5.9 Cummins intercooler is a great choice to replace custom intercooler to get improved service from your vehicles.
Banks 25980 Techni-Cooler Intercooler System For 5.9 Cummins
Technical Specifications:
Includes: Monster-Ram intake elbow and Boost Tubes (red powder-coated)
Fitment: 2003-2005 Dodge Ram 2500/3500 5.9L Cummins
Manufacturer: Banks
Value for money: πŸ”₯πŸ”₯πŸ”₯πŸ”₯πŸ”₯
Pros
Monster ram intake
Minimal boost pressure loss
Thick core and wide inlet-outlet
Improve power and fuel economy
Durable and vehicle fit option

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Mishimoto MMINT-RAM-94KSL Performance Intercooler Kit for Dodge Ram Cummins 5.9 1994-2002


Mishimoto MMINT-RAM-94KSL Performance Intercooler Kit for Dodge Ram Cummins 5.9 1994-2002
Mishimoto is a pioneer company that builds some brilliant intercooler kit for Dodge 1994-2002 5.9L Cummins. Their custom-made intercooler kit increases the lifespan of boots and also prevents leaks and blowouts.

It is known that performance lag and engine damage can be caused due to high intake and exhaust gas temperature. A quality intercooler like Mishimoto’s will ensure a substantial boost in performance and increased durability.

The quality of the Mishimoto intercooler is much better compared to a stock intercooler. So, it is worth it to spend some bucks to upgrade your intercooler.

Mishimoto kit can be found for a wide range of vehicles including the 2001 Dodge Cummins intercooler kit. So, now you can upgrade your 2001 Dodge easily and hassle-free.
Mishimoto Performance Intercooler Kit For 5.9 Cummins
Technical Specifications:
Direct fit: 12v and 24v 1994–2002 Dodge 5.9L Cummins
Includes: Hot-side and cold-side intercooler pipes and boots
Brand: Mishimoto
Value for money: πŸ”₯πŸ”₯πŸ”₯πŸ”₯
Pros
Direct for 12v and 24v Cummins
Includes both hot and cold side intercooler
Mishimoto lifetime warranty
47% increase in core volume
50% thicker than the factory cooler

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American Cooling Solutions 24432 Charge Air Cooler/Intercooler for Dodge Ram 2500, 3500 5.9L, 6.7L


American Cooling Solutions 24432 Charge Air Cooler/Intercooler for Dodge Ram 2500, 3500 5.9L, 6.7L
American cooling solutions company has made an outstanding intercooler kit for various models of vehicles for an affordable price. They made parts cheaper than others but as good as Banks, Mishimoto, and others. We recommend this product as our budget choice.

They offer both 5.9 Cummins intercooler piping and a 6.7 Cummins intercooler piping kit. This is an all-aluminum custom-made intercooler kit for Dodge ram trucks. It has got a 3” inlet and outlet module and can be replaced with a wide range of OEM part numbers.

Its’ heavy-duty extrude tubes are designed to provide ultimate airflow and heat transfer. You can consider this intercooler kit to replace your default intercooler system to get maximum service from your Dodge ram trucks. This one is a great value for money.
Technical Specifications:
Fits: 2003-2009 Dodge Ram 2500/3500 Cummins 5.9L and 6.7L
Brand: American Cooling Solutions
Value for money: πŸ”₯πŸ”₯πŸ”₯πŸ”₯
Pros
Available for a wide range of Dodge model
Fits both 5.9L and 6.7L
Heavy duty all aluminum made
100% leak tested
12 months of money back warranty

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1994-2002 Dodge Cummins Intercooler Boot Kit


1994-2002 Dodge Cummins Intercooler Boot Kit
Dieselspeedshop is a great company that produces an intercooler bootkit to give your vehicles a jump. This intercooler boot kit will fit a wide range of Dodge 5.9 Cummins and comes with both 12v and 24v direct-fit options.

This intercooler bootkit is made with silicone and also has got 5 layers of reinforcement. It has 8 stainless-steel spring-loaded bolt clamps.

A custom upgrade to the intercooler system can make a huge positive impact on the engine as factory intercoolers are not that much efficient thus compromises engine workability. So, if you are looking for a budget-friendly solution this can be an ideal choice.
Technical Specifications:
Fits: 12v and 24v Cummins, 1994-2002
Includes: Full silicone hoses, 5 layers of reinforcement
Value for money: πŸ”₯πŸ”₯πŸ”₯πŸ”₯
Pros
Heavy-duty silicone hoses
Stainless-steel spring-loaded bolt clamps
Can fit a model range from 1994-2002 Dodge Cummins
Have both 12v and 24c option
12 months warranty

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Mishimoto MMINT-RAM-03KBK Performance Intercooler Kit For Dodge Ram Cummins 5.9 2003-2007


Mishimoto MMINT-RAM-03KBK Performance Intercooler Kit For Dodge Ram Cummins 5.9 2003-2007
Mishimoto is a renowned company that makes some outstanding toolkit for vehicles. This performance intercooler kit is a great choice for all 2003-2007 Dodge 5.9 Cummins. It helps to supply improve airflow and to decrease air-charge temperatures. This is our premium choice.

Mishimoto has designed some of the best intercoolers till now. Like all other kits made by them, this intercooler is a masterpiece that helps vehicles to reduce exhaust gas temperatures and support your truck at any power level.

This kit is made of polished aluminum and Mishimoto used DuraCore technology which has more resistance to heat, pressure, oil, and fuel. You can choose this intercooler as an ideal kit for your Dodge 5.9 Cummins.

Each of the intercoolers mentioned above has got its unique features. But still, we tried to focus on the important ones to give you a better idea about it. And we think Banks intercooler kit which is the best value for money and has outstanding workability.
Mishimoto Performance Intercooler Kit For 5.9 Dodge
Technical Specifications:
Direct fit: 2003-2007 Dodge 5.9L Cummins
Construction: Bar-and-plate construction with cast aluminum end tanks
Brand: Mishimoto
Value for money: πŸ”₯πŸ”₯πŸ”₯πŸ”₯
Pros
Direct fit option for 2003-2007 Dodge 5.9 Cummins
Polished aluminum intercooler pipes
Improve airflow
Reduces pressure drop
Mishimoto lifetime warranty

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How to Install 5.9 Cummins Intercooler

Installing a 5.9 Cummins intercooler is very easy. All you need to do is to follow some instructions and do one by one like removing and placing parts accordingly.

You will need few tools like a 13mm socket, T20 and T30 Torx socket, Rachet and extension, Flathead screwdriver and Pick tool to install the 5.9 Cummins intercooler. It will take about 2 hours to install the kit with a moderate difficulty level.

First, you will have to unplug the battery and then other necessary clamp and tools. Once you are done with removing the hot and cold side pipe, remove the main pipe by pushing it back. Remove AC connector and radiator support. Then all you need to do is to place your new custom intercooler accordingly. Voila! You are done.

You can check this video that explains how to easily set up a custom intercooler into your vehicle.

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