Need advice! I just bought this 05' with all mods listed in my sig. The first time I really spooled the turbo it blew the whole intake side off of the intercooler.I'm told this is a common problem because they're made of plastic. Is there any cost-effective way to fix this problem without having to go with an aftermarket intercooler?

 

Your best bet, although costly, would be to go with a better intercooler. If money is good, Id definately get the BD intercooler, maybe overkill but that is one serious piece.

 

Thanks for the input. Yeah i was afraid somebody would say that... Not sure if I can swing the 1500 right now but my truck's down and I've gotta do something. How about those a
Arctic intercoolers? Any feedback on those?

 

I agree with promo 100% You will be better off buying a intercooler then you will have tons of room to grow. Plus the aftermarket intercoolers will lower your egts.

 

Or you can look through the classifieds. Someone may be getting rid of one off an 06 or 07 5.9L.

 

RAM CR 24V<

As stated above these years work out Great thats what I did and the 07.5-09 6.7s work to! They are made alittle different on the Tanks some what Better. Thats my next Cooler.

 

just like stated above get another stock one but get a metal one, not one with the plastic. You should be able to pic one up pretty cheap

 

the replacement one from dodge is now a one piece design.

 

Thanks for all the input fellas! I ended up buying an all aluminum 07 intercooler for that has been welded all the way around for $400 from Hamilton Diesel in Liberty Hill. Alex there told me they run 75 psi through them all the time without an issue

 

those guys know what they are talkin about you should be good!