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The Mishimoto 2nd-Generation Cummins Intercooler, Part 1: Project Intro and Factory Cooler Removal

Posted: February 26, 2015

Categories: Dodge Ram 5.9L Diesel Intercooler 1994-2002

Tags: turbo, teammishi, ram, muddin, mishimoto, merica, intercooler, holset, featured, dodge, diesel, 4x4, 3500, 2500

Interested in picking up our 2nd Gen Cummins intercooler or intercooler pipe kit? Check out the product pages linked below!

Dodge 5.9L Cummins Intercooler

Dodge 5.9L Cummins Intercooler Pipe & Boot Kit

12V and 24V Cummins in shop

After being hounded by second-generation owners for months, our team decided it was time to fulfill their needs and develop an awesome intercooler upgrade for the 12V and 24V. We would be designing our cooler with a few key features that would set it apart from the factory unit.

Cast aluminum end tanks for smooth airflow and unmatched durability
Extremely efficient bar-and-plate core
Direct fit for the 12V and 24V second-generation trucks

First Test Vehicle: 24V

After hunting around for a few local vehicles, this 24V ended up in our shop. A big thank you to the vehicle owner for lending us his truck for development.

24V Cummins in shop

Peering under the hood reveals a fairly clean engine bay.

24V Cummins factory engine bay

Factory 24V Cooler Removal

We didn't waste any time with this project and set to work removing the factory cooler from this truck. Along the way, we would be capturing measurements from the truck to see just how much we could expand the size of our intercooler design.

Removing factory intercooler

Factory intercooler removed

These trucks are relatively easy to work on and disassemble. We had the factory cooler out in a fairly short time.

Second Test Vehicle: 12V

Next, we rolled in a 12V truck to pull the cooler on this vehicle as well. By having both vehicles in the shop, we can ensure that our design will be applicable for vehicles with either engine.