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Call or Text (352) 722-5295Intake accessories for the 2004.5-2007 Ram 5.9L Cummins
The 5.9L intake tract has a lot of joints. Air goes from the airbox through the intake tube to the HE351CW turbo, then through rubber boots to the air-to-air intercooler, back to the cast aluminum air horn, through the grid heater and into the plenum cast into the head. Every joint between those parts is a gasket, a boot or a clamp, and that is most of what lives on this page. The rest is the electrical side: the grid heater element, its relay wiring, and the sensors that read manifold pressure and outside air temperature. Pilot injection on this common-rail engine works well enough that Cummins made the block heater optional, so the grid heater is the primary cold-start aid and worth keeping healthy.
What fails and why
Two leak points come up again and again. Factory rubber intercooler boots crack with age, and faster with added fuel or boost. The leak shows up as lost power, a whistle or hiss under boost, higher EGTs and black smoke. The air horn gasket is the other. The horn and grid heater must be unbolted for injector service, and the gasket tears easily on the way off. A torn gasket lets unmetered, unfiltered air in at the horn-to-head joint, which is exactly what your air filter is there to stop.
Stock replacement vs. upgrade
For the horn joint, stick with the right part: Cummins 3969988 is the heat-resistant gasket that replaced the old pink 3938158, and it is worth keeping a spare. For boots, silicone with spring-loaded clamps replaces the cracking factory rubber. Small intake changes, such as turbo air guide inserts or pulling the intake-tube silencer, are debated. Dyno results were small or inconsistent, so treat them as sound and response items, not power parts. If you run an oiled filter, go easy with the oil: over-oiled or poorly sealed cone filters show up as dust erosion on the turbo inducer wheel.
What we carry
Gaskets: the Alliant Power AP0058 intake grid heater gasket set, plus the MAHLE G32749 intake heater grid gasket, MS19355 intake manifold gasket set and HS54556 and HS54557 head sets for jobs that go deeper. Grid heater and sensors: a genuine Cummins 3969987 heater grid and 3971106 MAP sensor, and XDP heavy-duty relay-to-grid-heater wires, a grid heater relay fusible link wire and an ambient air temperature (AAT) sensor. Boots and clamps: a Mishimoto factory-fit boot kit, a WCFab 3.5-inch silicone boot and clamp kit, an S&B 4-inch silicone coupler with clamps and BD Diesel high-torque hose clamps. Filter care: the S&B Precision II cleaning and oil kit, the S&B WF-1017 filter wrap and the Banks Power pre-filter wrap for Ram-Air intakes. BD Diesel also offers positive air shutdowns in 3-inch, 3.5-inch and 2003-2007 Cummins-specific versions. The rest of this engine is on our Cummins hub.
Fitment notes
Several parts here carry wide year ranges in their titles (1989-2007, 1998.5-2007, 2003-2018), so read each listing rather than assuming. Boot and coupler kits are sold by inside diameter, so match the size of the pipe or the boot you are replacing. The head sets, the manifold gasket set and the Mishimoto boot kit are listed for 2003-2007 5.9L engines. If you have a 2007, confirm you have the 5.9L and not the 6.7L that replaced it on trucks built after January 1, 2007. When in doubt, verify by VIN.
Frequently asked questions
Can I reuse the air horn gasket after pulling the horn?
Do not count on it. The gasket tears easily when the horn comes off, and a torn one leaks unfiltered air into the engine. Cummins 3969988 is the heat-resistant replacement for the old pink 3938158, and the grid heater gasket should be replaced at the same time.
What causes a whistle under boost on my 5.9L?
A common cause is a cracked factory rubber intercooler boot. You will hear a hiss or whistle, and you may notice lost power, higher EGTs and black smoke. Silicone boots with spring-loaded clamps, like the Mishimoto factory-fit kit, replace the rubber ones.
Do turbo air guides or silencer changes make power?
Not reliably. Dyno testing showed small or inconsistent gains from turbo air guide inserts, and pulling the intake-tube silencer gained only about 1-2 hp, though spool improved. Think of them as sound and response changes.
Why does the grid heater matter so much on this engine?
It is the main cold-start aid. Pilot injection works well enough that Cummins made the block heater optional on the common-rail 5.9L, so the grid heater between the air horn and intake manifold does the work on cold starts. Its relay wiring and fusible link are on this page.
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.