2007.5-2009 Dodge 6.7L Cummins Air Intake Parts

Air intake on the 2007.5-2009 RAM 6.7L Cummins

Air enters a fender-mounted box with a paper panel filter and heads to the Holset HE351VE variable-geometry turbo. From the compressor it runs through the hot-side boot and tube to the front-mounted air-to-air intercooler, back through the cold-side tube and boot, and into a cast intake horn that carries the grid heater plate. From there it feeds the intake manifold, which is cast into the cylinder head. There are no glow plugs on this engine. The grid heater does all of the cold-start work, and that is why the horn is the most important intake part on the truck. The factory filter is Mopar 53034051AB, also sold as Fleetguard AF27684, on a 30,000-mile or 24-month interval.

What fails and why

The grid heater bolt. The stud and nut that hold the heater plate in the intake horn can loosen with age and heat and drop into the intake. The engine sits at a 5-degree rake, so loose hardware rolls rearward to cylinder #6. Symptoms run from misfire, knock and loss of power to a destroyed engine. It has earned the name killer grid heater bolt.

Intercooler boots. The factory rubber boots crack, leak and blow off under boost, and added boost makes it worse. Watch for a boost-leak whistle, black smoke, low boost, limp mode or a boot you can see has popped off.

Soot. Cooled EGR puts soot into the intake. Over high miles it builds up in the elbow and manifold and restricts airflow. You feel it as a slow loss of response and see it as higher EGT.

Dirt. A neglected or poorly sealed filter lets dust reach the VGT compressor wheel. A dusted wheel brings turbo whine and oil consumption.

Stock replacement vs. upgrade

If your intake is stock and healthy, keep the filter on schedule and check the boots. When a boot blows, the Mishimoto MMBK-RAM-07BK factory-fit kit puts four 5-layer silicone boots with T-bolt clamps in the stock locations. On a stock truck the cold-side boots are held by crimped metal bands that have to be cut off. If the intercooler or tubes are also tired, Mishimoto's 2007.5-2009 kit pairs a bar-and-plate core and cast end tanks with 3.5-inch mandrel-bent pipes, silicone boots and T-bolt clamps.

For the grid heater, the Banks Monster-Ram 42797 replaces the factory horn with a high-flow elbow and an integrated 750-watt coil heater, so you keep cold-start function. Banks benches the stock elbow at about 38.6 lb/min and rates the Monster-Ram at an 88% flow gain without tuning. It carries CARB EO D-161-170. Up front, the Banks Ram-Air cold air intake claims up to 28 hp and 52 lb-ft, 50% less restriction and lower EGT. Several brands build intakes for this truck, and CARB EO numbers are listed per product, so check the listing before you buy.

What we carry

• Grid heater fixes: the BD Diesel Killer Grid Heater Upgrade Kit, the Banks Power Monster-Ram in pickup and chassis cab versions, and XDP heavy-duty grid heater relay fusible link wire.
• Intakes and filters: the S&B 75-5093 cold air intake kit, the Banks 42175 Ram-Air, a Wehrli Custom Fabrication 4-inch intake kit and filter, and replacement elements and pre-filters from S&B, Banks and Fleece Performance Engineering.
• Intercoolers and boost tubes: Mishimoto, CSF and Banks intercoolers, Banks boost tube kits, Mishimoto boot kits and PPE silicone couplers.
• Sensors: MAF, IAT, AAT and MAP sensors and connectors from Cummins, XDP and Alliant Power, plus G&R Diesel sensor bungs.
• Gaskets and hoses: MAHLE intake manifold, throttle valve and head gasket sets, genuine Cummins upper engine gasket kits and a Dorman intake hose.
• Shutdowns: BD Diesel positive air shutdown valves.

For the rest of the engine, start at the Cummins hub, or compare complete kits on our intakes page.

Fitment notes

The 6.7L arrived mid-2007, replacing the 5.9L, so engine and intake parts for the 2007.5 trucks are their own fitment. Read the year range in every title. The Mishimoto boot kit fits 2007-2009 6.7L only, not the 2003-2007 5.9L or 2010-2012 trucks. The Monster-Ram 42797 does not fit chassis cabs; a 3500 Chassis Cab takes the separate chassis cab version. Banks splits its intercooler upgrade by year, with one part for 2007.5-2008 and another for 2009. Some listings, like the CSF intercoolers, span 2003-2009 5.9 and 6.7L, while the Mishimoto MMB-RAM-002 bundle is for the 2003-2007 5.9L only. The 4500 and 5500 chassis cabs ride on a different chassis, and most pickup parts do not interchange. When in doubt, verify by VIN.

Frequently asked questions

What is the killer grid heater bolt?

It is the stud and nut that hold the factory grid heater plate in the intake horn. With age and heat it can loosen and drop into the intake, and because the engine sits at a 5-degree rake, it rolls back to cylinder #6. The result can be a misfire, a knock or a destroyed engine. The BD Diesel upgrade kit and the Banks Monster-Ram both target that weak point, and the Monster-Ram keeps cold-start heat with its built-in 750-watt coil.

How often should I change the air filter on a 2007.5-2009 6.7L?

The factory interval for the stock element, Mopar 53034051AB or Fleetguard AF27684, is 30,000 miles or 24 months. Diesel Hub lists frequent air filter checks as turbo-failure prevention, because dust that gets past a neglected or poorly sealed filter damages the VGT compressor wheel. If you run an aftermarket intake, use the replacement element made for that kit.

How do I know an aftermarket intake is emissions-legal?

Look for the CARB EO number on the product listing. EO numbers are issued per product, not per brand. The Banks Monster-Ram intake horn, for example, carries CARB EO D-161-170. If a listing does not show one, call us before you order.

Why did my intercooler boot blow off?

The factory rubber boots crack and leak with age, and added boost speeds that up. You may hear a whistle, see black smoke, feel low boost or get limp mode. The Mishimoto factory-fit kit swaps in 5-layer silicone boots with T-bolt clamps at the stock locations. Plan on cutting the factory crimped bands to get the cold-side boots off.

Does the intake get dirty inside on a high-mileage truck?

Yes. Cooled EGR puts soot into the intake, and Banks states the stock intake collects soot over time and restricts airflow. On high-mileage trucks that shows up as slower response and higher EGT. If the horn is coming off for grid heater work, the MAHLE intake manifold gaskets here cover the reassembly.

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.