Intercooler Bar and Plate for 2003-2009 Dodge Ram 2500/3500 5.9L/6.7L Diesel | SPELAB
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---tab Description---
5.9L/6.7L Cummins Bar-and-Plate Intercooler Overview
The 5.9L and 6.7L Cummins engines are legendary for making massive, tire-shredding torque. But pushing high boost and heavy loads through the factory plastic-tank intercooler is a recipe for disaster. Whether you're towing a 20,000 lb gooseneck trailer or running a high-boost compound turbo setup, you need an intercooler built to handle extreme pressure and heat.
Enter the SPELAB Heavy-Duty Bar-and-Plate Intercooler. We ditched the weak factory crimped plastic tanks and replaced them with indestructible Cast Aluminum End Tanks , mated to a massive 3.35-inch Bar-and-Plate core .
Boasting a 34% larger core volume and massive 3.5-inch inlet/outlets , this competition-grade intercooler dramatically reduces restriction. It acts as a massive thermal sponge, absorbing temperature spikes to drastically lower your Exhaust Gas Temperatures (EGTs) and Intake Air Temperatures (IATs). Upgrade to SPELAB to extend your turbo's life, maximize your tuning potential, and permanently bulletproof your Cummins charge air system.
Bar-and-Plate Intercooler Fitment
• 2003 Dodge Ram 2500/3500 5.9L Diesel
• 2004 Dodge Ram 2500/3500 5.9L Diesel
• 2005 Dodge Ram 2500/3500 5.9L Diesel
• 2006 Dodge Ram 2500/3500 5.9L Diesel
• 2007 Dodge Ram 2500/3500 5.9L Diesel
• 2007 Dodge Ram 2500/3500/4500/5500 6.7L Diesel
• 2008 Dodge Ram 2500/3500/4500/5500 6.7L Diesel
• 2009 Dodge Ram 2500/3500/4500/5500 6.7L Diesel
Heavy-Duty Intercooler Key Features
• Indestructible Cast Aluminum End Tanks
Tuned Cummins engines can easily push 50-80+ PSI of boost. Factory plastic tanks will explode under this pressure. Our solid cast aluminum end tanks provide unmatched structural integrity and smooth internal airflow, capable of holding 100+ PSI without ballooning or leaking.
• Massive 3.35" Bar-and-Plate Core
Featuring a 34% increase in core size over the stock 2.48-inch unit. This heavy-duty bar-and-plate construction provides immense thermal capacity—crucial for preventing heat soak during long, heavy towing grades or intense sled pulling.
• High-Flow 3.5" Inlet & Outlet
Cummins engines need to breathe. We engineered this intercooler with massive 3.5-inch connections to ensure maximum airflow volume, reducing pressure drop and allowing large single or compound turbo setups to spool faster and hit harder.
• Drastic EGT Reduction
By delivering a significantly cooler, denser air charge to the intake manifold, this intercooler directly combats the dangerously high EGTs often experienced in tuned or heavy-towing 5.9L and 6.7L trucks.
• Premium T-Bolt Clamps Included
To ensure your connections hold up to extreme Cummins boost, we include premium constant-tension T-bolt clamps for a blowout-proof installation at the intercooler joints.
Product Specifications
Core Dimensions and 100+ PSI Boost Rating
Core Type
Heavy-Duty Bar-and-Plate
End Tank Material
Cast Aluminum Alloy
Core Thickness
3.35 in
Core Dimensions
27.36" L x 25.57" H
Overall Dimensions
40.3" L x 27.6" H x 6.2" W
Inlet / Outlet Size
3.50 in (Max Airflow Capacity)
Max Boost Rating
100+ PSI Capable
---tab FAQ---
Cummins Bar-and-Plate Intercooler FAQs
Q: Why do I need Cast Aluminum tanks for my Cummins?
A: The Cummins engine generates massive torque and high boost pressures, especially when tuned. The OEM intercooler uses plastic tanks crimped onto the core, which are notorious for blowing apart. Cast aluminum provides the strength needed to hold extreme boost safely and permanently.
Q: I tow heavy loads with my 6.7L. Will this help lower my EGTs?
A: Yes, absolutely. The thick 3.35-inch bar-and-plate core absorbs the extreme heat generated during long, heavy pulls. By supplying cooler air to the engine, it significantly reduces Exhaust Gas Temperatures (EGTs), keeping your engine in the safe zone.
Q: Will this support a truck with upgraded turbos and big injectors?
A: Yes. With its massive 3.5-inch inlet/outlets and high-capacity core, this intercooler is overbuilt to handle the airflow demands of heavily modified 5.9L and 6.7L engines pushing high horsepower.
Q: Is this a direct drop-in replacement?
A: Yes, despite its massive size, it is engineered to be a direct-fit replacement using the factory mounting points.
Q: Are the clamps included?
A: Yes, the package includes premium constant-tension T-bolt clamps for the intercooler connections. (
Note:
Intercooler piping and silicone boots are sold separately).
Q: Do you sell Cummins intercoolers for other model years?
A: Yes! If your truck is a 2010-2012 Ram, we have the 2010-2012 6.7L Cummins bar-and-plate intercooler . And if you'd like a tube-fin core for your 2003-2009, we also carry the 2003-2009 5.9L/6.7L Cummins tube-fin intercooler .
---tab Shipping & Returns---
Fast Shipping Policy
Your order will be dispatched within 1-2 business days , and the package will arrive within your order's estimated date. Click for Shipping Policy
Easy Return Policy
Every order comes with a 14-day free return , which means you don't have to pay for a return slip. Click for Return Policy
---tab Description---
5.9L/6.7L Cummins Bar-and-Plate Intercooler Overview
The 5.9L and 6.7L Cummins engines are legendary for making massive, tire-shredding torque. But pushing high boost and heavy loads through the factory plastic-tank intercooler is a recipe for disaster. Whether you're towing a 20,000 lb gooseneck trailer or running a high-boost compound turbo setup, you need an intercooler built to handle extreme pressure and heat.
Enter the SPELAB Heavy-Duty Bar-and-Plate Intercooler. We ditched the weak factory crimped plastic tanks and replaced them with indestructible Cast Aluminum End Tanks , mated to a massive 3.35-inch Bar-and-Plate core .
Boasting a 34% larger core volume and massive 3.5-inch inlet/outlets , this competition-grade intercooler dramatically reduces restriction. It acts as a massive thermal sponge, absorbing temperature spikes to drastically lower your Exhaust Gas Temperatures (EGTs) and Intake Air Temperatures (IATs). Upgrade to SPELAB to extend your turbo's life, maximize your tuning potential, and permanently bulletproof your Cummins charge air system.
Bar-and-Plate Intercooler Fitment
• 2003 Dodge Ram 2500/3500 5.9L Diesel
• 2004 Dodge Ram 2500/3500 5.9L Diesel
• 2005 Dodge Ram 2500/3500 5.9L Diesel
• 2006 Dodge Ram 2500/3500 5.9L Diesel
• 2007 Dodge Ram 2500/3500 5.9L Diesel
• 2007 Dodge Ram 2500/3500/4500/5500 6.7L Diesel
• 2008 Dodge Ram 2500/3500/4500/5500 6.7L Diesel
• 2009 Dodge Ram 2500/3500/4500/5500 6.7L Diesel
Heavy-Duty Intercooler Key Features
• Indestructible Cast Aluminum End Tanks
Tuned Cummins engines can easily push 50-80+ PSI of boost. Factory plastic tanks will explode under this pressure. Our solid cast aluminum end tanks provide unmatched structural integrity and smooth internal airflow, capable of holding 100+ PSI without ballooning or leaking.
• Massive 3.35" Bar-and-Plate Core
Featuring a 34% increase in core size over the stock 2.48-inch unit. This heavy-duty bar-and-plate construction provides immense thermal capacity—crucial for preventing heat soak during long, heavy towing grades or intense sled pulling.
• High-Flow 3.5" Inlet & Outlet
Cummins engines need to breathe. We engineered this intercooler with massive 3.5-inch connections to ensure maximum airflow volume, reducing pressure drop and allowing large single or compound turbo setups to spool faster and hit harder.
• Drastic EGT Reduction
By delivering a significantly cooler, denser air charge to the intake manifold, this intercooler directly combats the dangerously high EGTs often experienced in tuned or heavy-towing 5.9L and 6.7L trucks.
• Premium T-Bolt Clamps Included
To ensure your connections hold up to extreme Cummins boost, we include premium constant-tension T-bolt clamps for a blowout-proof installation at the intercooler joints.
Product Specifications
Core Dimensions and 100+ PSI Boost Rating
Core Type
Heavy-Duty Bar-and-Plate
End Tank Material
Cast Aluminum Alloy
Core Thickness
3.35 in
Core Dimensions
27.36" L x 25.57" H
Overall Dimensions
40.3" L x 27.6" H x 6.2" W
Inlet / Outlet Size
3.50 in (Max Airflow Capacity)
Max Boost Rating
100+ PSI Capable
---tab FAQ---
Cummins Bar-and-Plate Intercooler FAQs
Q: Why do I need Cast Aluminum tanks for my Cummins?
A: The Cummins engine generates massive torque and high boost pressures, especially when tuned. The OEM intercooler uses plastic tanks crimped onto the core, which are notorious for blowing apart. Cast aluminum provides the strength needed to hold extreme boost safely and permanently.
Q: I tow heavy loads with my 6.7L. Will this help lower my EGTs?
A: Yes, absolutely. The thick 3.35-inch bar-and-plate core absorbs the extreme heat generated during long, heavy pulls. By supplying cooler air to the engine, it significantly reduces Exhaust Gas Temperatures (EGTs), keeping your engine in the safe zone.
Q: Will this support a truck with upgraded turbos and big injectors?
A: Yes. With its massive 3.5-inch inlet/outlets and high-capacity core, this intercooler is overbuilt to handle the airflow demands of heavily modified 5.9L and 6.7L engines pushing high horsepower.
Q: Is this a direct drop-in replacement?
A: Yes, despite its massive size, it is engineered to be a direct-fit replacement using the factory mounting points.
Q: Are the clamps included?
A: Yes, the package includes premium constant-tension T-bolt clamps for the intercooler connections. (
Note:
Intercooler piping and silicone boots are sold separately).
Q: Do you sell Cummins intercoolers for other model years?
A: Yes! If your truck is a 2010-2012 Ram, we have the 2010-2012 6.7L Cummins bar-and-plate intercooler . And if you'd like a tube-fin core for your 2003-2009, we also carry the 2003-2009 5.9L/6.7L Cummins tube-fin intercooler .
---tab Shipping & Returns---
Fast Shipping Policy
Your order will be dispatched within 1-2 business days , and the package will arrive within your order's estimated date. Click for Shipping Policy
Easy Return Policy
Every order comes with a 14-day free return , which means you don't have to pay for a return slip. Click for Return Policy
SPELAB Auto Parts: 1 year from delivery; supplier conditions apply. SPELAB offers a one-year limited warranty from delivery for material/workmanship defects under normal use, original purchaser only, with proof of purchase. Consumables, wear/cosmetic damage, improper installation, alteration, misuse and removal/installation labor are excluded. Approved remedies are repair, replacement or replacement parts at SPELAB’s discretion.
Return and warranty information is based on what SPELAB Auto Parts offers. Product-specific eligibility and the supplier’s published conditions apply; FullSpecDiesel does not add or extend coverage.
SPELAB Auto Parts warranty policyView complete warrantyProduct conditions
Return and warranty information is based on what SPELAB Auto Parts offers. Product-specific eligibility and the supplier’s published conditions apply; FullSpecDiesel does not add or extend coverage.
- Return eligibility
- SPELAB allows return requests within 30 days of delivery, with authorization and undamaged goods, original packaging and accessories. Tuners are final sale. Customer pays voluntary return shipping; original shipping is not refunded. SPELAB pays return shipping for approved damaged, incorrect or manufacturing-defective items. Transit damage must be reported within two business days and incorrect items within seven days. Based on what SPELAB Auto Parts offers.
- Return window
- Not stated for this product; see supplier terms
- Restocking fee
- See supplier terms; no product-specific fee stated
- Return shipping
- Based on the supplier’s return policy; see terms
- Made to order
- No
- Backorder status
- Not backordered
- Cancellation
- Subject to supplier terms; contact FullSpecDiesel before requesting cancellation
- Warranty provider
- SPELAB Auto Parts
- Warranty duration
- 1 year from delivery; supplier conditions apply
- Compatibility
- Listed for specific vehicle configurations
- Legal use
- Street legal
- Processing estimate
- 3–10 business days supplier processing
- Shipping
- Shipping calculated at checkout
- Signature
- No signature requirement
- Supplier
- SPELAB Auto Parts
Product compatibility is based on the vehicle and product information provided. Review your selected truck, product options, measurements, modifications, and installation requirements before ordering.