Intercooler Pipe & Intake Manifold Kit for 2003-2007 Dodge Ram 2500/3500 5.9L Diesel | SPELAB

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3.5" Intercooler Pipe & Intake Manifold Kit for 5.9L Cummins

If you are using your 2003-2007 5.9L Cummins the way it was meant to be used—towing heavy loads, running performance tunes, or hitting off-road trails—the factory 3-inch intercooler piping is holding you back. Aging stock rubber hoses expand and blow off under high boost, while the restrictive factory intake horn chokes your engine of the cold, dense air it needs. The result? Sluggish throttle response, climbing Exhaust Gas Temperatures (EGTs), and the constant fear of a roadside breakdown.

Bulletproof Your Cummins Breathing System.
The SPELAB 3.5" Intercooler Charge Pipe & Intake Elbow Kit is the ultimate airflow overhaul for your 3rd-Gen Cummins. We replace the entire restrictive factory system (both hot and cold sides) with massive 3.5-inch mandrel-bent aluminum tubing and a high-flow intake elbow.

Paired with heavy-duty silicone boots and constant-tension spring clamps, this kit ensures perfectly smooth, unrestricted airflow from your turbo, through the intercooler, and directly into the engine. Whether you are hauling a 5th wheel up a steep grade in the summer heat or maximizing a new tune, you’ll experience faster turbo spool, significantly lower EGTs, and total peace of mind.

FFitment: 2003-2007 Dodge Ram 2500/3500 5.9L Diesel

• 2003 Dodge Ram 2500/3500 5.9L Diesel
• 2004 Dodge Ram 2500/3500 5.9L Diesel
• 2005 Dodge Ram 2500/3500 5.9L Diesel
• 2006 Dodge Ram 2500/3500 5.9L Diesel
• 2007 Dodge Ram 2500/3500 5.9L Diesel

Key Features of the SPELAB 5.9L Cummins Intercooler Pipe & Intake Manifold Kit

• Massive 3.5" High-Flow Tubing
  Upgrades the restrictive 3-inch factory pipes to 3.5-inch mandrel-bent aluminum. Reduces internal flow resistance, allowing your turbo to push a massive volume of cold air with zero turbulence for instant throttle response.

• High-Flow Intake Elbow Included
  Replaces the cramped factory intake horn with a smooth, optimized geometry. Removes the final bottleneck before the intake manifold, drastically improving engine breathing and lowering EGTs under heavy loads.

• Constant-Tension Spring Clamps
  Unlike standard clamps that loosen when cold, our stainless steel spring clamps automatically adjust to extreme thermal expansion and contraction. Delivers a vice-like, 360-degree grip that guarantees your boots will never blow off, even under maximum boost pressure.

• High-Pressure Silicone Boots
  Upgrades the weak, aging factory rubber to multi-layer, heat-resistant silicone. Prevents ballooning and tearing under high boost and intense engine bay temperatures.

• Direct-Fit OEM Replacement
  Precision-engineered to utilize factory mounting points. Enjoy a seamless, straightforward installation without the need for custom fabrication or permanent engine modifications.

• Rugged Lightweight Construction
  Made from premium, precision-machined aluminum with a sleek black finish. Provides the extreme durability required for off-road and towing applications while keeping unnecessary weight off the front end.

Product Specifications

Pipe Diameter	3.5 Inches (Upgraded from 3.0" OEM)
Tubing Material	Mandrel-Bent Aluminum
System Components	Hot Side Pipe, Cold Side Pipe, Intake Elbow
Boot Material	High-Temperature Reinforced Silicone
Clamp Style	Stainless Steel Constant-Tension Spring Clamps
Gross Weight	4.5 kg (Approx. 9.9 lbs)
Emissions Status	NOT CARB COMPLIANT (Off-Road/Race Use Only)

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FAQ

Q: Does this kit include both the hot and cold side pipes?
A: Yes! This is a complete, comprehensive system. It includes the Hot Side (Turbo to Intercooler), Cold Side (Intercooler to Engine), and the Intake Elbow.

Q: Do I need a custom tune to run this kit?
A: No custom tune is required. This is a direct-fit hard part that improves efficiency and lowers EGTs on a completely stock truck. However, if you are running a tuner, this kit will help you maximize those horsepower gains safely.

Q: Why do you use spring clamps instead of standard T-Bolt clamps?
A: Diesel engines go through extreme temperature swings. Standard clamps cannot adjust, often leading to loose boots when the engine cools. Our stainless spring clamps maintain constant, dynamic pressure through all heat cycles, providing the ultimate blowout-proof seal.

Q: Will this fit my 2008 6.7L Cummins?
A: No. This kit is specifically designed for the 2003-2007 5.9L Cummins. The 6.7L engine utilizes a different intake layout and requires a different kit.

Q: Is this product street-legal in California?
A: No. This product does not have a CARB (California Air Resources Board) Exemption Order. It is strictly for off-road or organized racing use only.

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