1998.5-2002 Dodge 5.9L Cummins Intake Horns

The intake horn on the 1998.5-2002 Ram 5.9L Cummins

On the 24-valve 5.9L Cummins, boosted air leaves the front-mounted intercooler and climbs through a cast intake horn into the intake manifold. The electric grid heater is sandwiched between the horn and the manifold, and it is the only cold-start aid on this engine. That stack of horn, grid heater and manifold is why a horn swap always involves the grid heater and its gaskets.

Why owners change the horn

Horn upgrades on this truck are about flow. The angular shape of the factory piece promotes turbulence, and its small diameter creates a bottleneck. Aftermarket horns answer with a larger plenum, smooth radius turns and added gauge ports, which gives smoother flow into the manifold. If you are chasing low power or a boost leak rather than flow, check the intercooler boots first, since they are the usual leak in this system, and rule out a dirty or failed MAP or intake air temperature sensor.

Stock replacement vs. upgrade

If the factory horn is staying, the job is resealing. Fresh Mahle gaskets for the grid heater and the intake manifold put it back together sealed. If you are upgrading, the S&B 76-1007 intake elbow and the Banks Monster-Ram intake system are the horn-side upgrades on this page, both listed for 1998.5-2002 trucks. Whichever way you go, keep the grid heater in the stack. Some aftermarket horns relocate it and some sandwich it, but the engine needs it to start cold.

What we carry

• S&B 76-1007 performance intake elbow, listed for 1998.5-2002 5.9L Cummins.
• Banks Power 42764 Monster-Ram intake system, listed for 1998.5-2002 Cummins.
• Mahle G32749 intake heater grid gasket and MS12435 intake manifold gasket set.

Cold air intakes for the front of the system are on our intakes page.

Fitment notes

The S&B elbow and the Banks Monster-Ram are listed for 1998.5-2002 only, so they are 24-valve parts and are not listed for the earlier 12-valve trucks. The Mahle gaskets cover a wider range of 5.9L Cummins years. Before you order a horn, check how it handles the grid heater and whether it adds the gauge ports you want. For a truck registered in California, confirm the CARB EO number on intake parts. Verify by VIN or call us.

Frequently asked questions

Is the stock intake horn really a restriction?

It is the restriction the aftermarket targets on this truck. The factory horn has an angular design that promotes turbulence, and its smaller diameter creates a bottleneck. Aftermarket horns add plenum volume and smooth radius turns for smoother flow.

Will I lose my grid heater with an aftermarket horn?

You should not, and you do not want to. The grid heater is the engine's only cold-start aid. Some horns relocate it and some keep it sandwiched like the factory setup, so confirm the design before you buy.

Which gaskets do I need for a horn swap?

The grid heater sits between the horn and the manifold, so plan on a heater grid gasket and an intake manifold gasket set. The Mahle G32749 and MS12435 listed here cover both joints.

Not sure what fits? Call the shop at the number in the header, or use the fitment checker on any product page. We install everything we sell.