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!
Click here to skip to our recommended pick!
- 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: 🔥🔥🔥🔥🔥
- Purchase link: Buy your Banks 25980 Techni-Cooler Intercooler System For 2003-2005 Cummins 5.9 L at Amazon!
- 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: 🔥🔥🔥🔥
- Purchase link: Buy your Mishimoto MMINT-RAM-94KSL Performance Intercooler Kit for Dodge Ram Cummins 5.9 1994-2002 at Amazon!
- Fits: 2003-2009 Dodge Ram 2500/3500 Cummins 5.9L and 6.7L
- Brand: American Cooling Solutions
- Value for money: 🔥🔥🔥🔥
- Purchase link: Buy your American Cooling Solutions 24432 Charge Air Cooler/Intercooler for Dodge Ram 2500, 3500 5.9L, 6.7L at Amazon!
- Fits: 12v and 24v Cummins, 1994-2002
- Includes: Full silicone hoses, 5 layers of reinforcement
- Value for money: 🔥🔥🔥🔥
- Purchase link: Buy your 1994-2002 Dodge Cummins Intercooler Boot Kit at Amazon!
- Direct fit: 2003-2007 Dodge 5.9L Cummins
- Construction: Bar-and-plate construction with cast aluminum end tanks
- Brand: Mishimoto
- Value for money: 🔥🔥🔥🔥
- Purchase link: Buy your Mishimoto MMINT-RAM-03KBK Performance Intercooler Kit For Dodge Ram Cummins 5.9 2003-2007 at Amazon!
Our Overall #1 Rated Pick
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.
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
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.
Mishimoto MMINT-RAM-94KSL Performance Intercooler Kit for Dodge Ram Cummins 5.9 1994-2002
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.
American Cooling Solutions 24432 Charge Air Cooler/Intercooler for Dodge Ram 2500, 3500 5.9L, 6.7L
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.
1994-2002 Dodge Cummins Intercooler Boot Kit
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.
Mishimoto MMINT-RAM-03KBK Performance Intercooler Kit For Dodge Ram Cummins 5.9 2003-2007
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.
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.
