How To: Install A Banks Ram-Air Intake On A Dodge 6.7 Cummins

Most people see large diesel trucks as tools for accomplishing a job. What most people don't realize is that with a few choice modifications, a modern turbodiesel truck can produce an absolutely obscene amount of weapons-grade power.  I recently spent a few hours up to my elbows in a Cummins 6.7-powered Ram 3500, installing a Gale Banks Engineering Ram Air Intake, and the quality of the parts and the general insanity of the install inspired me to share some pictures and impressions with you all.

This is what we're starting with: a 6.7L Cummins ISB-powered Ram 3500.  This is the latest and greatest powerplant from Cummins, who has supplied diesel engines to Dodge for decades.  This massive iron-block inline 6 makes 350 horsepower, but more importantly, 650lb-ft of torque.  For you Europeans, that would be 881 Newton-Meters for reference.  It's also fully emissions compliant thanks to a trick DPF (diesel particulate filter) setup, meaning there's no black smoke!  The stock intake setup is on the left side.

While the stock engine already makes lots of power, and almost more torque than you know what to do with, there's always room for improvement.  The intake pulls air from inside the fender on the left, runs it through a big square filter in the housing, and then through an IAT and MAF sensor on that tube, to the turbo.  It's not a bad intake setup, but it's rather restrictive in a few areas.

Like, for instance, this big baffled and bellowed mass of crap that Dodge calls a turbo inlet pipe.  You've gotta be kidding me!  A monster of an engine like this deserves a REAL intake.

Here are some of the Banks parts, from left to right: Filter housing, top of housing, "Super Scoop" cold air intake setup.  Feet in picture are size 13, just for scale.  That's a massive intake there, buddy.

And here is the Banks Turbo Inlet Pipe, plus the rubber bellows and a silicon coupler.  Again, all these parts are what I'd like to call Texas-sized.  With the Ram-Air setup and the optional "Super Scoop" cold-air intake, Banks claims gains of 39bhp and 69lb-ft of torque, which should theoretically bring the totals up to 389bhp and 719(!) lb-ft of torque (974nM.)  Let's get started.

Obviously, the first step is to remove all the old crap.  I didn't bother to take pictures of removing every bit of old intake, as you'll see how the aftermarket one goes back together.  The filter housing is held in place with one locating nut tied to the radiator support, and it pushes into place through a few rubber grommets to hold still and vibration-free.  Basically, from there you loosen and remove all the worm-gear hoseclamps, and do some pulling and yelling, and this is whatcha get: a big 'ol turbo just sitting there.  The big silver pipe that's not visible with the filter housing in place is the intercooler charge pipe, by the way.  This is one of those trick Holset VGT (Variable Geometry Turbos) which can open or close the compressor vanes to allow for quicker spool at low RPM, and tons 'o boost at high RPM.  Now all it needs is a decent source of air...

Now, the Banks intake can be installed one of two ways: as a regular Ram-Air setup, or with the optional Super Scoop (man, they could've picked a less goofy name!) which pulls cold air from below the bumper.  To use the huge scoop, you've got to cut the bottom of the filter housing off, 1" from the bottom all around.  A hacksaw or an electric-powered handsaw works best, because this is some thick plastic.  Oh, and about that filter...

It's pretty large!

This is the view through the filter housing with the Super Scoop attached.  The scoop sits in front of the fender liner, then turns 90° to face out the front of the bumper.  The Banks filter housing uses the stock mounting points, which is nice.

Next, you mount the turbo inlet pipe.  Now, this looks fairly easy - there's PLENTY of room to work - but the big problem here is how damn large this truck is.  To actually reach down in there and have leverage to turn wrenches, you're gonna need one foot on a step stool, and one foot on the bumper.  Be sure not to slip off and slam the family jewels on the grille guard like I did.

The Turbo inlet pipe attaches to the turbo with that swanky Banks silicon coupler and two worm-gear clamps.  Notice that the Banks pipe also has a fitting for the PCV (positive crankcase ventilation) hose - attached with a spring clamp and a worm-gear clamp - so you don't get a check engine light.  The Mass Air Flow sensor (MAF) is transferred to the Banks inlet pipe, and the Intake Air Temperature sensor moves to the top chunk of the filter housing.  The trick is to tighten the band-clamp on the turbo side but leave the clamp on the inlet pipe side loose so you can properly align it with the housing.  Also, a tiny bit of WD40 on the inside of the PCV hose makes it WAY less difficult to get onto the fittings.

After the inlet pipe is in place, the rest is fairly straightforward.  You swap the filter-minder (that red/yellow/green thing on the bottom right) over to the top part of the filter housing, seperate the IAT and MAF sensor wiring to give yourself some more room, and bolt everything together.  The rubber bellows (there to allow for engine movement under load) is secured by two huge worm-gear clamps; the top of the filter housing uses three humongous screws.  All fairly straightforward, actually.

With everything in place, it actually looks sort of OEM- very high quality stuff!  The fit & finish is remarkably good, and the sound - oh, boy, the sound is epic.  I'm pretty sure that Holset can be heard spooling for about a 1-mile radius.  The truck has noticeably more low-end shove that before with this setup, and it's got a snarl to it that is a bit alarming to dogs and small children.  Hey, I'd be concerned too if I was at risk of getting sucked up this intake.  Squirrels, also.

Bottom line: highly recommended for anyone with a Cummins-powered Ram.  Go get one!