2003-2004 Dodge 5.9L Cummins Cold Air Intakes

Intakes on the 2003-2004 Ram 5.9L Cummins

The factory system is a sealed airbox at the radiator support, fed only from the passenger fender, with a fender liner that isolates the inlet from under-hood heat. The inlet is about 19 square inches. From the box, a 4 in tube carries air to the turbo on the 5.9L Cummins. The 2004.5 trucks got a larger inlet, a cold-air baffle and no fender liner, which is why 2003-2004 intakes are often cataloged separately from 2004.5-2007 intakes.

Where the factory intake holds you back

TDR's testing on these trucks found the paper filter is the biggest restriction and the small box inlet is the second, with the tube after that. In TDR's dyno work on a 2004 Ram 3500 dually with the 305 hp High Output engine and an NV5600, opening the sealed box inlet by 12 square inches and ducting cool air to it improved boost response and peak power above 2,700 rpm. An open-element filter with a heat shield made the same power only with the hood open. The takeaway is that a cold-air feed matters more than an exposed filter.

Stock replacement vs. upgrade

On a stock truck, the factory system holds its own. Diesel Power magazine tested six aftermarket intakes against a stock 2005 system on a stock truck and none beat it, and TDR concluded that airflow is set by displacement, rpm, volumetric efficiency and boost rather than by the filter. Once you add fuel, an intake that opens up the inlet and feeds it cold air makes sense. For a street truck, choose a kit with a CARB EO number. Banks and S&B are among the brands that offer EO-numbered intake kits.

What we carry

The S&B 75-5094 cold air intake kit fits 2003-2007 5.9L trucks and comes with a choice of a cleanable cotton filter or a dry extendable filter. Banks Power offers the RAM-Air cold air intake for 2003-2007 Cummins trucks. Wehrli Custom Fabrication has a 4 in intake kit and the Stage 2 high-flow intake bundle kit for 2003-2007 5.9L trucks. Mishimoto makes a black silicone air intake hose for the same years, and the MAHLE MS19355 intake manifold gasket set is here for work on the manifold side. For every truck we cover, see all intakes.

Fitment notes

The airbox, intake tube and fender liner differ between 2003-2004 and 2004.5-2007, so intake kits are year-split. Most kits here are listed for 2003-2007 and cover both, but always confirm the years in the title. Bundle kits include more than the airbox, so read what is in the kit before you plan the install. These parts are for the Dodge Ram 2500 and 3500 only. Verify by VIN if you are not sure.

Frequently asked questions

Is a cold air intake worth it on a stock 5.9L?

Usually not for power alone. Diesel Power magazine's test of six aftermarket intakes found none beat the stock system on a stock truck, and TDR reached the same conclusion. The case for an intake gets stronger once fueling has been added.

Is an open-element intake better than a sealed box?

Not in TDR's testing on this truck. A sealed box with a larger inlet and ducted cool air improved boost response and power above 2,700 rpm, while an open element with a heat shield made the same power only with the hood open.

Can I run a cold air intake on a street truck?

Yes, if it carries a CARB EO number for your truck. Banks and S&B are among the brands that offer EO-numbered intakes, so check the product page for the EO number before you order.

Should I pick the cotton or dry filter on the S&B kit?

The S&B 75-5094 comes with either a cleanable cotton filter or a dry extendable filter. TDR found cotton flows the most but gives up a little filtration efficiency and dirt-holding capacity, and recommended stock or dry media for towing and dusty use.

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.