Banks Power Intercooler Upgrade Kit

Dodge Ram 2500/Ram 3500 09 6.7L Diesel/5.9L Diesel

Part #: 25985

Overview

The Banks Power Intercooler Upgrade Kit is engineered to deliver safer, more reliable power for your 2009 Dodge Ram 2500 or 3500 equipped with the 6.7L Cummins engine. Designed to replace the factory intercooler system, this upgrade features significantly larger components that improve airflow and cooling capacity. By increasing air density and reducing boost air temperatures, it enhances combustion efficiency, resulting in higher continuous power output, improved fuel economy, and lower exhaust gas temperatures (EGTs).

This kit is ideal for diesel enthusiasts and professionals seeking to maximize their truck’s performance while maintaining durability and efficiency under demanding conditions.

Key Features

The Banks Intercooler Upgrade Kit combines advanced engineering and premium materials to optimize your truck’s intake air cooling and flow. Key features include:

• Mandrel-bent 3.5-inch high-flow boost tubes for minimal airflow restriction
• Custom-machined, durable cast aluminum end tanks for superior heat dissipation
• Wide-open inlet and outlet ports with 31% larger cross-sectional area than stock
• 12% thicker intercooler core area, significantly increasing cooling volume
• Enhanced air density for improved combustion and engine efficiency
• Reduced boost pressure loss to maintain optimal turbocharger performance
• Lower exhaust gas temperatures for safer, sustained power delivery
• Includes all necessary mounting hardware for a straightforward installation
• Backed by a 2-year warranty for peace of mind

Construction & Design

The Banks intercooler system is built with high-quality materials designed to withstand the rigors of heavy-duty diesel applications. The core features a 12% thicker design compared to stock, increasing the volume of air it can cool efficiently. The end tanks are precision-machined from durable cast aluminum, providing excellent thermal conductivity and structural integrity. Mandrel-bent 3.5-inch boost tubes ensure smooth airflow transitions, minimizing turbulence and pressure drop. This robust construction not only enhances performance but also ensures long-term reliability in demanding environments.

Performance & Sound

By dramatically increasing the cooling capacity and airflow volume, the Banks Intercooler Upgrade Kit helps your engine breathe cooler, denser air. This results in improved combustion efficiency, which translates to higher continuous power output without the risk of excessive exhaust gas temperatures. The system reduces boost pressure loss, allowing your turbocharger to operate more effectively. While primarily focused on performance and durability, the improved airflow can also contribute to a smoother engine sound characteristic of efficient turbo operation.

Installation & Fitment

This upgrade kit is designed specifically for the 2009 Dodge Ram 2500 and 3500 models equipped with the 6.7L Cummins engine, ensuring a precise fit. Installation involves replacing the factory intercooler components with the larger Banks parts, utilizing the included mounting hardware. While professional installation is recommended for best results, experienced enthusiasts can perform the upgrade with standard hand tools. No major modifications are required, making it a direct bolt-on solution that enhances your truck’s performance and reliability.

What's Included

• Mandrel-bent 3.5-inch high-flow boost tubes
• High-efficiency cast aluminum end tanks
• Intercooler core with 12% thicker design
• Wide-open inlet and outlet components
• Complete mounting hardware kit
• Installation instructions

Ideal For

This intercooler upgrade is perfect for Dodge Ram 2500 and 3500 owners who demand more from their 6.7L Cummins diesel. Whether you tow heavy loads, haul frequently, or simply want to improve your truck’s power and efficiency, this kit provides a reliable solution. It is especially beneficial for those running higher boost levels or seeking to maintain lower EGTs during extended heavy-duty operation.

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.