As I am on the verge of upgrading the original plastic sided intercooler, I just want to get some observations from those who have already done this.

Obviously, the intercooler is important for making power. Knowing that the discharge air can be 500+ degrees, and the cool side of an aftermarket cooler will be 125, just how much difference can be realized for a non-twin setup such as mine.

I seem to recall a formula that relates charge air temp to HP based on density. I don't recall the math. It was a significant amount. I believe it also applies to our diesels. There is also a CFM (airflow) improvement.

I have heard that 30-40HP can be relized from this alone. I am inclined to think this and even more given conditions. I live where it is 93+ deg. every day and 93% humidity now. I know when we have a few precious moments of cooler weather, my truck feels stronger.

Chris

 

I changed my plastic intercooler with a Banks kit. When I changed my turbo from BD single to HTT 62/12 my palstic intercooler popped. The dealer (A holes) didn't want to warranty it, so I picked up the Banks kit. I did notice when I felt the intercooler by hand, the driver side of the intercooler is much cooler than the passenger side when the engine was reving @ 1600 rpms.

 

at the time I am testing the inlet air temp to outlet air on the stock intercooler and then will be installing a spearco intercooler from turbonetics and I will give you an update on how it works. Turbonetics has a nice bolt in replacement intercooler for the dodge trucks. 94-02 part no. 2-479 03-05 part no. is 2-477

 

Sorry to hi jack, but is the banks kit worth the money??? im gonna replace mine and was wondering if it was worth it.

 

Banks kit , NO, Banks intercooler , Yes.

Rick

 

why not the kit. i have been told the kit works pretty good. they say it keeps it cool and can add power lost from the stock intercooler because of its design.