Intercooler Bar and Plate for 2003-2009 Dodge Ram 2500/3500 5.9L/6.7L Diesel | SPELAB

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

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).