Intercooler

Remove and replace the intercooler on a 2007 Ram 3500 with 5.9L Cummins diesel engine, including removal of charge air cooler piping and mounting hardware.

Warnings

Tools required

Parts

• Intercooler assembly × 1 — Use OEM or equivalent charge air cooler
• Charge air cooler inlet boot/clamp × 1 — Replace if damaged
• Charge air cooler outlet boot/clamp × 1 — Replace if damaged
• Intercooler mounting hardware × 1 — Inspect and replace as needed

Fluids

• HOAT coolant 50/50 — 2 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Allow engine to cool completely for at least 2 hours
3. Disconnect both battery cables, negative first
4. Raise front of vehicle and secure on jack stands rated for vehicle weight
5. Remove engine belly pan or skid plate if equipped
6. Place drain pan beneath intercooler area

Procedure

1. 1

   Remove upper charge air cooler tube
   Locate the charge air tube connecting the turbocharger outlet to the intercooler inlet on driver side. Loosen the hose clamps at both the turbocharger outlet and intercooler inlet using flathead screwdriver or socket. Carefully remove the tube assembly. Immediately cover the turbocharger outlet with a clean plastic bag and secure with rubber band to prevent contamination.
2. 2

   Remove lower charge air cooler tube
   From underneath the vehicle, locate the charge air tube running from intercooler outlet to intake manifold on passenger side. Loosen hose clamps at intercooler outlet and intake manifold connection. Remove the tube assembly and set aside. Cover the intake manifold opening immediately with plastic or clean shop towels to prevent debris entry.
3. 3

   Disconnect transmission cooler lines if equipped
   The 2007 Ram 3500 uses an air-to-air charge air cooler; the transmission cooler is integrated into the radiator, NOT the intercooler. No transmission cooler lines connect to the intercooler, so no transmission lines need to be disconnected to remove the charge air cooler. Place drain pan beneath connections. Using appropriate wrench, carefully loosen and disconnect transmission cooler lines. No transmission fluid is present in an air-to-air intercooler, so no ATF will drain during this procedure. This step does not apply to the 2007 Ram 3500 Cummins intercooler.
4. 4

   Remove intercooler mounting bolts
   Locate the four intercooler mounting bolts securing intercooler to radiator support and frame brackets. Two bolts are accessible from top near grille area, two from underneath. Remove all four mounting bolts and set aside with any spacers or insulators for reinstallation.
5. 5

   Remove intercooler assembly
   Carefully maneuver the intercooler downward and forward out of the vehicle. The intercooler must clear the radiator and A/C condenser. May need to angle slightly to clear frame rails. Have assistant support intercooler from below if needed. Once removed, drain any accumulated oil or condensation into drain pan and inspect for damage.
6. 6

   Inspect and clean mounting area
   Inspect intercooler mounting brackets and rubber isolators for damage or deterioration. Clean all mounting surfaces of dirt, debris, and old sealant. Inspect charge air tubes and boots for cracks, oil saturation, or deterioration. Replace any damaged components.
7. 7

   Prepare new intercooler
   Unbox new intercooler and compare to old unit to verify correct application. Check that all mounting holes align and fittings match. If intercooler has integrated transmission cooler, verify orientation of cooler line fittings matches original. Remove any protective caps or shipping plugs.
8. 8

   Install new intercooler
   Carefully position new intercooler into vehicle, angling as needed to clear radiator and frame rails. Align mounting holes with brackets. Install rubber isolators if equipped, then thread in mounting bolts finger-tight. Verify intercooler is positioned correctly and clearances are adequate before tightening.
9. 9

   Tighten intercooler mounting bolts
   Tighten all four intercooler mounting bolts in a cross pattern to ensure even seating. Tighten firmly but do not overtighten as this may crack the plastic end tanks. Verify intercooler is secure and properly seated against all mounting points.
10. 10

    Reconnect transmission cooler lines
    If equipped with integrated transmission cooler, remove plugs from cooler lines and fittings. Connect transmission cooler lines to intercooler fittings and tighten securely. Verify lines are not kinked or touching hot exhaust components. Check for proper thread engagement before final tightening.
11. 11

    Install lower charge air tube
    Remove protective covering from intake manifold. Position lower charge air tube between intercooler outlet and intake manifold. Install hose clamps but do not fully tighten yet. Verify tube is properly seated on both connections with no gaps or misalignment, then tighten clamps securely.
12. 12

    Install upper charge air tube
    Remove protective covering from turbocharger outlet. Position upper charge air tube between turbocharger outlet and intercooler inlet. Install hose clamps but do not fully tighten. Check for proper alignment and seating, ensuring tube does not contact other components. Tighten clamps securely once properly positioned.

Reassembly

1. Reinstall engine belly pan or skid plate if equipped
2. Lower vehicle from jack stands
3. If transmission cooler lines were disconnected, check ATF+4 level and add fluid as needed to reach proper level
4. Reconnect battery cables, positive first then negative
5. Perform visual inspection of all connections before starting engine

Verification

• Start engine and allow to idle, monitoring for any unusual sounds or vibrations
• Check all charge air tube connections for air leaks while engine is running (listen for hissing sounds)
• If transmission cooler equipped, inspect transmission cooler line connections for leaks
• Allow engine to reach operating temperature and verify no coolant or fluid leaks from intercooler area
• Test drive vehicle and monitor boost pressure gauge if equipped - should reach normal boost levels (typically 25-30 PSI under load)
• After test drive, re-inspect all connections for leaks or looseness
• If transmission cooler equipped, recheck ATF+4 level after reaching operating temperature and top off if necessary

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