Shibby Engineering Stage I intake, 8263 mile evaluation on stock 2009 6.7l Cummins. I decided to try this and leave the emissions crap on to see if I could get any mileage gain. The product info:
Technical Information:
All Stage I intakes come in cast aluminum with black powder coating standard
Direct bolt on to any truck for lower EGTs, increased MPG, HP, and torque.
Trucks will pass emissions testing with this intake installed.

Lets start with the intake itself. It is a very well done product, nice casting and machined finish. It bolted right up in place of the factory horn without any drama.

Lower EGT’s, I cannot make any comments on this statement as it is a stock truck with no gauges.

Increased MPG, here’s where it gets weird. I am getting better mileage as long as it stays below 64 degrees outside. Once it gets above that, the fan clutch engages like I’m pulling 26k up a 7% grade in 100 degree heat. The engine is well below 200 degrees as this is happening. The fan only shuts down when it is time to regen. The fan on is killing the mileage. Regen time has increased, burning more fuel and my wallet. In talking to many people more knowledgable than me, it seems that the smaller intercooler on the 2009 is the culprit.

HP and torque, based on seat of the pants and 140k miles in one year, does seem to be up a little. It pulled most of my familiar grades better with all of the different trailers I transport. I did not have to downshift as early or not at all. Acceleration is better too. With a bigger opening, it almost acts like the power curve gets steeper with RPM but is a little dog off idle. Once it is past 1800 rpm we are of to the races. Again, the intercooler could be the biggest problem here.

Passing emissions, it should, the exhaust is still clean.

I have one more trailer to deliver and by the time I get home, I will have over 10k miles on the intake. I will remove it to see how much soot collected inside. Will be reinstalling the factory horn to see if the fan problem goes away. Then the big decision, test a bigger cooler or go to the dark side (Black tec). I certainly have the time and ability to rack up the miles in a short amount of time.

 

Cool

Nice write up

Now do a grid heater delete and see a dramatic change.

I was one of the first to get a stage 1, 2 years ago. I forget it's there. I did a grid heater delete a few months ago and it was a dramatic difference. I also did the shibbey heater install.

I picked up 2 MPG with those mods

If you don't need the grid heater, yank it

 

the 03-08 intercooler will bolt right in. friend here in town just sold his 09 and got an 11. he came over to my place and we installed an earlier intercooler into his 09. he said his EGT's alone dropped 150 degrees and was more responsive.

 

I installed a 2007 5.9L intercooler in my '09. The difference is apparent:



It was very easy, and only took 30min or so.





Didn't mean to derail this thread, just thought that I would share some pictures. Thank you for the information on the intake horn.

Scott.

 

Aketay did the Grid heater delete as well. The product looks good too on there.

I am thinking the software is trying to compensate the intake air with more EGR flow?? If the intake air is cool it will cycle the EGR to increase it. I wonder if the IAT sensor is fouled and is sending an erratic signal to the ECM and causing your issue.

Anyway, Smarty will fix your problem!!

 

Initial testing over at 11,200 miles. Shibby is removed and factory is back on. The fan situation is back to normal. Will be saving intake for another day. I suspect with the EGR ports not being diverted as in the stock intake, the hot (cooled ) exhaust gases blow directly on the MAP looking sensor which is directly across from the EGR. Even at this low mileage, the soot buildup is impressive. At ten times the mileage it seems the soot would be over 1/4 inch. Time to get back out there and make some more money to fund research.

 

Good observation. The EGR flow seems like the culprit to mess up your cooling system setpoints. It must think that the intercooler is too hot and starts to cycle the fan.

BTW, I got my DOC down pipe put in, nice to have it breathe clearly now. The exhaust note is louder however, I know that was a concern for your long hours on the road. Next time through eh?

Smarty money....

 

Back on the road now, delivering a mud jacking trailer to Coutts, AB. Then back to pick another one up for Uncle Ben's. Took a few liberties with the Dremel and a bur to clean up the factory intake. 800 miles into this trip and all is well except for the 30 mph headwind. More to come in the near future, the Shibby idea is not dead. Amazing how quick you can get used to small power gains.