Heavy-Duty Bar-and-Plate Intercooler

The SPELAB Heavy-Duty Bar-and-Plate Intercooler is engineered to replace the weaker, factory plastic-tank intercooler in 2003-2009 Dodge Ram 2500/3500 trucks equipped with 5.9L or 6.7L Cummins engines. This competition-grade intercooler boasts a massive 3.35-inch bar-and-plate core, offering a 34% larger volume than stock units and significantly reducing restriction. Its construction features indestructible cast aluminum end tanks, capable of withstanding over 100 PSI of boost without failure, unlike the OEM plastic tanks which are prone to exploding under high pressure. With high-flow 3.5-inch inlet and outlet connections, this intercooler ensures maximum airflow volume, leading to faster turbo spool and improved performance. It acts as a substantial thermal sponge, effectively absorbing heat spikes to dramatically lower Exhaust Gas Temperatures (EGTs) and Intake Air Temperatures (IATs). This upgrade is crucial for extended turbo life, maximizing tuning potential, and bulletproofing the Cummins charge air system, especially for those towing heavy loads or running high-boost compound turbo setups. Key features include the robust cast aluminum end tanks, the substantial 3.35-inch bar-and-plate core for superior thermal capacity, and the high-flow 3.5-inch connections. Premium constant-tension T-bolt clamps are included for secure installation at the intercooler joints, ensuring a blowout-proof connection. The intercooler is designed as a direct-fit replacement utilizing factory mounting points. However, note that intercooler piping and silicone boots are sold separately, and some users have reported needing to acquire 6mm bolts for condenser mounting and that stock boots will not fit.