I just had the dealer replace the intercooler on the 2005 ram 3500. The end crimp to the plastic tank came loose. I'm not sure what the boost pressure was, but the Edge/Attitude was set to de-fuel at 36psi?

So what options do I have for a better intercooler?
I thought Banks has a VNT Turbo/intercooler package, but they don't list it on their web page.

 

I am not positive but I think the 03 had a all steel tank . Probably pick one up from a wrecker at a reasonable price .

 

the 03-04 were aluminum tanked charge air coolers... and tommygun had some pics of a brand new 05 he has on his lot over on the tdr and it has aluminum end tanks... seems like the plastic is gone???

 

I have plastic on my 05

I'm not to the point of upgrading it yet, but when my warranty is up (5-6 years!) then I'll probably be ready for an upgrade

 

Why would you wait until the warranty is up?
That doesnt make sense.

Rant: People use the excuse not to modify because of warranty, but if something breaks in or out of warranty do to a mod your still going to have to fix it yourself.

Rant over.

If the upgrade made my truck more reliable I would forget about what the paper warranty says.

 

I had my intercooler blow an end cap as well. They are not rated very high at all. But, according to my mech at Dodge it is a prob that is occurring more than it should.

 

Tomeygun has posted over on TDR that the late 05s are apparently coming with the all-aluminum again. Apparently, the plastic has been a problem even on stock trucks.

I have an 04.5, and, to tell the truth, I have never noticed whether mine was aluminum or plastic. I'll have to take a look. Considering I can easily hit 32-33 lbs boost on my stock truck, I hope it is metal.

 

It would not surprise me to see a TSB on the plastic-tanked intercoolers soon....I saw the pic posted by Tomeygun over on the TDR as well.....sure enough, the later production 2005's have the all metal intercoolers on them again. I have a friend with an '05 that "robbed" {swapped out} his dad's '03 intercooler already !
Greg

 

AMEN! My experience with Edit is just that, they are thieves!

 

well i just poped my intercooler today. AND MY BOX WAS OFF! because i dont like to run it when im towing heay and it still poped it

 

Anyone with an '05 continuously hit 40PSI+ on their plastic intercooler and NOT have it pop? For those that popped theirs, how long had you had the box installed before it blew?

 

Yep,

Crazy huh?

I am selling one today, and its an 05 with a metal cooler now. Thank the lord

AND I have then in stock in the parts dept. about :
55056593AA -about $500+/- with shipping

 

Uh yeah with my quad box im seeing 40 psi on every good mashing on the higher settings. see 30-35 a lot too on just a decent highway acceleration. if she lasts till august ill be estatic.

 

Dealer denies any problems with intercoolers. Mine blew apart while on vacation to San Felipe, Mexico. 65 MPH level highway towing 8000 lbs of toys. Dealer in Calexico no help. No intercoolers available on the West Coast. 318 on BO on the West Coast. Limped into San Felipe where my sons and I repaired the intercooler. Held fine back home, 700 miles. Local dealer has metal tanked units on his lot, and I think he is going to assist with a replacement. We will see.

 

I run 42psi everyday, and lucky it hasn't popped yet. Then again, it's nothing Merrick, me, and some chewing gun can't fix