The Banks Monster Ram Intake System is a high-performance modification for the 2019–2023 RAM 2500 and 3500 trucks equipped with the 6.7L Cummins engine. Designed to enhance airflow efficiency and engine responsiveness, the system replaces the factory intake components with a custom-built solution tailored for improved performance. This guide compiles detailed installation instructions based on official manufacturer manuals and technical documentation from Banks Performance. The article focuses on key steps, hardware requirements, and critical warnings to ensure a safe and accurate installation process.
Overview of the Banks Monster Ram Intake System
The Banks Monster Ram Intake System includes a billet aluminum intake plate, custom gaskets, fuel rail spacers, and all necessary hardware for installation. The system is engineered to integrate seamlessly with the existing engine architecture while optimizing airflow and reducing intake restriction. The installation involves the removal of factory components such as the EGR valve, throttle body, and various sensors, followed by the transfer of these components to the new intake system. Special attention is required for the coil heater, temperature sensors, and wiring harness routing to maintain proper function and prevent damage.
The system is available in different configurations depending on the vehicle model year and cab type. For example, the standard intake system is designed for 2019–2023 RAM 2500/3500 models, while the Chassis Cab variant (4500/5500) includes unique mounting points and sensor placements due to differences in engine bay design. Both configurations require similar installation procedures, although specific steps may vary for Chassis Cab models.
Pre-Installation Preparation and Tools
Before beginning the installation, it is essential to gather all required tools and verify that the correct parts are included in the kit. The following tools are recommended for the installation:
- Socket and wrench set (including 8mm, 10mm, and 1/4" hex bit)
- Rubber mallet
- Thread locker (medium strength)
- Adhesive spray
- Telescoping magnet
- Cleaning supplies (solvent, rags, Scotch-Brite pad)
- Torque wrench (capable of 18–20 ft-lbs)
It is also important to ensure that the vehicle is parked on a flat surface and that the engine is completely cool. The installation should be performed in a well-ventilated area, as fuel and solvent vapors can be hazardous. Users are advised to wear appropriate protective gear, including gloves and safety glasses.
Step-by-Step Installation Guide
Step 1: Identify and Prepare the Fuel Line
Before beginning the installation, visually inspect the kit to confirm which fuel line is included. Different model years may require different fuel line configurations, and using the correct component is essential for a proper fit. Once the correct fuel line is identified, proceed with the following steps.
Step 2: Remove and Prepare the OEM Components
The first major step in the installation process is the removal of the factory intake components. This includes the EGR valve, throttle body, and various sensors. These components must be carefully removed to avoid damage, as they will be transferred to the new intake system.
To remove the EGR valve, disconnect any associated hoses and sensors. Use a rubber mallet to gently tap the throttle body free from the intake manifold if it is stuck. Be cautious not to damage the gasket surfaces during this process. After removal, clean the mating surfaces with a solvent and a soft cloth to ensure a proper seal with the new intake system.
Step 3: Transfer Sensors and Components
Once the factory components are removed, the next step is to transfer the sensors and wiring to the new intake system. The billet aluminum plate includes provisions for temperature sensors and the MAP sensor. These sensors must be carefully removed from their original locations and installed in the corresponding ports on the new intake plate.
The temperature sensor, in particular, requires special attention. It must be transferred to the Banks billet plate without over-tightening, as the aluminum is softer than the steel threads on the sensor. Over-tightening can cause the sensor to bottom out or damage the threads. A small amount of medium-strength thread locker should be applied to the sensor threads before installation to ensure a secure fit.
Step 4: Install the Gaskets and Billet Plate
The intake system includes custom gaskets designed to fit the new intake plate and engine manifold. These gaskets must be applied with adhesive to ensure a secure and leak-free seal. The adhesive should be applied to the Banks side of the gasket, and the gasket should be allowed to tack up for approximately 3 minutes before installation.
Once the gasket is ready, align the bolt holes and stick it to the flat side of the billet plate. Use a small amount of medium-strength thread locker on the bolts before tightening them to 18 ft-lbs. It is important to follow a cross-pattern tightening sequence to ensure even pressure distribution and prevent warping.
Step 5: Install the EGR and Throttle Body Components
After the billet plate is installed, the next step is to mount the EGR and throttle body components to the new intake system. The EGR gaskets must be placed on the Monster-Ram, and the EGR bolts must be tightened to 18 ft-lbs. Apply a small amount of medium-strength thread locker to the bolts before tightening.
The throttle body gasket should be aligned and fastened to the Monster-Ram using the same torque specifications. Care must be taken to ensure that the gasket surfaces are clean and free of debris to prevent leaks. Once the throttle body is mounted, the engine harness should be routed under the dipstick and around the valve cover, following the manufacturer’s recommended path.
Step 6: Secure the Monster-Ram and Final Adjustments
The final step in the installation process is securing the Monster-Ram into the boost tube. A long bolt should be inserted into the front corner by hand to help hold the Monster-Ram in place. Repeat this for the backside and the two smaller bolts. A telescoping magnet is recommended for starting the bolts in the middle of the Monster-Ram, especially for the small bolt that is difficult to reach.
Once all bolts are in place, use a hex key extension to tighten them to 18–20 ft-lbs. It is important to start with the bolt that is inside the Monster-Ram and work in a cross pattern to torque to spec. After the bolts are tightened, slide the copper washer onto the heater coil and tighten the coil heater by hand, ensuring that it is tight but not over-tightened.
Finally, install the dipstick tube bracket and connect the remaining components, including the forward flat blue injector plug and the forward PCV hose. Ensure that all connections are secure and that the engine harness is properly routed to avoid interference with moving parts.
Special Considerations for Chassis Cab Models
For RAM 3500/4500/5500 Chassis Cab models, certain installation steps may differ due to variations in the engine bay layout. The MAP sensor, for example, is located on the rear of the intake manifold and must be transferred to the corresponding port on the Monster-Ram. Additionally, the thermocouple temp sensor may be mounted on the manifold plate, and users should transfer this sensor to the billet plate if it is present.
Users should also note that the billet heater plate may be transitioning to a cast design (42731) with integrated fuel rail spacers. If the kit includes this cast heater plate, the fuel rail spacers will not be included and this step can be skipped.
Conclusion
The Banks Monster Ram Intake System offers a robust and reliable solution for enhancing the performance of 2019–2023 RAM 2500/3500 6.7L Cummins engines. By following the detailed installation instructions provided in this guide, users can ensure a successful and safe installation. The process involves the careful removal and transfer of factory components, the installation of custom gaskets and hardware, and the precise tightening of bolts to manufacturer specifications. Special attention should be given to sensors, wiring, and gasket surfaces to maintain proper function and prevent leaks.
For Chassis Cab models, additional considerations must be made due to differences in engine bay design. Users are encouraged to consult the official installation guides and support resources provided by Banks Performance for any model-specific variations. With the right tools, preparation, and attention to detail, the installation can be completed efficiently and effectively, resulting in improved engine performance and reliability.