Banks Power Intercooler Upgrade

2003–2005 Dodge Ram 2500/3500 5.9L Cummins

Part #: 25980

Overview

The Banks Power Intercooler Upgrade is a high-performance cooling solution designed specifically for the 2003 to 2005 Dodge Ram 2500 and 3500 equipped with the 5.9L Cummins engine. This upgrade replaces the stock intercooler system with a larger, more efficient setup that significantly improves air density and cooling capacity. Ideal for enthusiasts and professionals seeking enhanced continuous power, improved fuel economy, and reduced exhaust gas temperatures, the Banks Techni-Cooler system ensures your Cummins engine runs cooler and more efficiently under demanding conditions.

By increasing the volume and flow of cooled air entering the engine, this intercooler upgrade supports better combustion and engine efficiency, resulting in higher sustained power output and improved durability. Whether you tow heavy loads, haul off-road, or simply want to maximize your truck’s performance, the Banks Power Intercooler Upgrade delivers reliable, measurable benefits.

Key Features

This intercooler upgrade incorporates advanced design and engineering to maximize airflow and cooling efficiency. Key features include:

• Large 3-1/2 inch mandrel-bent boost tubes for superior airflow
• Thicker intercooler core with 27% more flow volume than stock
• High-efficiency, custom-machined durable cast aluminum end tanks
• Wide-open inlet and outlet design to minimize boost pressure loss
• Includes the Monster-Ram intake manifold for enhanced air delivery
• Balances richer fuel mixtures with cooler, denser air for improved combustion
• Reduces exhaust gas temperatures (EGTs) for better engine longevity
• Improves fuel economy by optimizing air density and combustion efficiency
• Superior aluminum end tank design for durability and heat dissipation
• Comes with all necessary mounting hardware for straightforward installation

Construction & Design

The Banks Techni-Cooler system is engineered with durability and performance in mind. The intercooler core is 20% thicker than the factory unit, providing a substantial increase in cooling surface area and flow volume. The end tanks are precision-machined from high-quality cast aluminum, offering superior strength and heat dissipation compared to stock plastic or thin metal components.

Mandrel-bent 3.5-inch boost tubes ensure smooth, unrestricted airflow with minimal turbulence, while the wide-open inlet and outlet ports reduce pressure drop, preserving boost pressure for maximum engine response. The Monster-Ram intake manifold is designed to complement the intercooler by delivering a steady stream of cool, dense air directly into the cylinders.

Performance & Sound

By significantly lowering intake air temperatures and increasing air density, the Banks Power Intercooler Upgrade enhances combustion efficiency, resulting in higher continuous power output and improved throttle response. Cooler intake air also helps reduce exhaust gas temperatures, which protects engine components and allows for more aggressive tuning. While primarily focused on performance and efficiency, this upgrade contributes to a smoother and more responsive driving experience without altering engine sound characteristics.

Installation & Fitment

This intercooler upgrade is designed as a direct fit for 2003–2005 Dodge Ram 2500 and 3500 trucks equipped with the 5.9L Cummins engine. Installation requires no major modifications and includes all necessary mounting hardware for a straightforward bolt-on upgrade. Professional installation is recommended to ensure optimal fitment and performance.

What's Included

• Large 3-1/2 inch mandrel-bent boost tubes
• Thicker intercooler core with enhanced flow volume
• Custom-machined cast aluminum end tanks
• Monster-Ram intake manifold
• Wide-open inlet and outlet components
• Complete mounting hardware kit

Ideal For

This intercooler upgrade is perfect for Dodge Ram 2500 and 3500 owners with the 5.9L Cummins engine who demand higher continuous power, improved fuel economy, and enhanced engine durability. It is especially beneficial for those who tow heavy loads, engage in off-road driving, or seek to optimize their truck’s performance in demanding conditions.

Banks Power develops emissions-compliant performance parts for diesel and gas trucks, SUVs, and tow rigs—focused on airflow, efficiency, and reliable power. With decades of engineering and patented development, Banks offers systems like intakes, exhaust and boost upgrades, tuners, and supporting components designed to increase performance while maintaining drivability for real-world use.