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Part #: BD1042525

BD-Power 1042525 Cool-It Intercooler

2003-2009 Dodge 5.9L/6.7L Cummins
Part #: BD1042525
  3 Reviews
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  3 Reviews


The BD-Power 1042525 Cool-It Intercooler is designed with streamlined external air passages improves engine cooling while offering less fan noise and less blade resistance, plus, improving engine power and efficiency of the radiator and air conditioning heat exchangers. Designed through testing at 100+ psi turbo boost pressure and 500oF turbo outlet temperatures, our extra thick cast end tanks with support struts have integrity and long life without ballooning and cracking.

Stuffed Tube designs are commonly used on stock applications with boost pressures of 20-40 psi and 200-300F inlet temperatures. The tubes have a thin wall and 82% heat conductivity transfer. Higher boost pressures and temperatures will cause breaking of fin-to-wall welds resulting in tubes ballooning and reduced heat transfer.

Micro Extruded Tube design is for applications producing 20-100 psi of boost pressure and inlet temperatures of 500+F. The tubes have a 0.025 wall thickness and designed enhanced inner fins that add to performance and already strong support structure resulting in a 95% heat conductivity transfer. No cracking or separation occurred when tested at over 400 psi.
The lower the turbo boost pressure drop across the CAC (inlet vs. outlet) the higher the volume flow the more volume of air that can flow through the CAC and the higher the turbo boost pressure will result in lower exhaust gas temperatures (EGT).

  • Extruded Tube Design
  • Extra Thick Cast End Tanks
  • Includes Everything Needed For Installation

Includes: Intercooler, (2) Intercooler Boots, (4) Clamps, Hardware & Instructions

Additional Information

Install Sheet


  • MFG. Number1042525
  • Manufacturer NameBD-Power
  • Shipping Weight63.00 lb.
  • Shipping Length44 in.
  • Shipping Width7 in.
  • Shipping Height3 in.


Location: New Jersey
Just installed this intercooler and air tube and had no issues installing it on my 07 5.9 ram. Smoother power band and lower exhaust temps. 100 deg easy.
Does as promised
Location: South Texas
Living in south Texas you will find that it is very hot down here. Even on the hottest of days(even before I installed my BD Super B Special) I had drops of 100-150 degrees. With the EGT probe mounted just above the flange I definitely have an accurate guage reading. My truck is a 2wd quad cab and at night I've seen as low as 590 degrees at 70mph with the BD Pulse exhaust manifold, the BD Super B Special, and the BD Cool-It intercooler. I also added the BD metal boost tube for the driver side as the existing one is plastic. Definitely worth the wait/money.
Easy to install - will work with an 09
Location: NJ
Great product! Easy to install & very well built. My intake temps are now 15 degrees over ambiant at full operating temperature on a warm day! If you own an 09 with the 6.7, this part will fit with no issues. I had to do NO modifications whatsoever. Even though BD states 2003-2008, this will fit your 2009. I highly recommend this item.

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Emissions Notice

This product is not legal for sale or street use in California. Certain aftermarket products are subject to governmental emission standards regulated by the California Air Resources Board. In order for these products to be legal on a specific vehicle in California, the part number must receive a CARB Executive Order (EO) number. This number makes the part legal for use only on specific years, makes and models of vehicles. A decal with CARB EO number for these parts must be displayed in the engine bay to satisfy smog inspection requirements.