The Intake Air Heater, also known as a heater grid, is an essential component in Dodge Ram 6.7L diesel engines to ensure efficient cold-weather starts. However, the factory heater assembly can become a serious liability. One of the biggest design flaws of the stock configuration is the fastener on the underside of the intake plate.
Over time, the nut and bolt can melt due to high amperage draw from the heater circuit. Vibration from the engine can then cause it to fall down into the intake plenum. Without anywhere else to go, this damaged fastener typically makes its way into cylinder #6. This can result in bent valves, damaged pistons, and even the need for a complete engine rebuild or replacement due to catastrophic engine failure.
What is a Heater Grid?
Unlike traditional glow plugs found in other diesel engines, the Dodge Ram 6.7L diesel, much like its predecessor the 5.9L, utilizes a heater mounted between the intake manifold (or elbow) and cylinder head. This system works by heating the incoming air before it reaches the cylinders, helping ensure optimal combustion in cold start conditions. However, the stock design restricts airflow, reducing throttle response and overall engine efficiency.
Common Causes of Grid Heater Failure
Failure is typically caused by three main factors: amperage draw, vibration, and time. The amperage draw caused by the heater circuit can melt the fasteners, causing them to loosen. Continuous engine vibrations further contribute to the nut falling into the intake. Additionally, as the vehicle ages, wear and tear can increase the likelihood of failure, making older models particularly susceptible to this dangerous issue. Fortunately, Banks, a leader in diesel engineering, has developed a solution to eliminate this risk, the Banks Monster Ram Intake & Heater Grid Upgrade.
The Consequences of Grid Heater Failure
Numerous documented cases from Banks highlight the devastating effects of grid heater failure such as:
- Abe’s Ram 6.7L Failure: Abe’s 2017 Ram 6.7L experienced grid heater failure at just 100k miles. Despite purchasing a Banks Monster Ram as a preventative measure, he delayed installation. Unfortunately, only five miles into a trip, his engine began to knock and stumble. The grid heater bolt had broken off, destroying piston #6, bending both intake valves, and cracking the head. His repair bill reached five digits, proving how costly this failure can be.
- Crisis Averted: Chris, a Ram 3500 owner, installed the Banks Monster-Ram intake with the grid heater upgrade as a precaution. Upon removing the OEM intake, he found corrosion on the bolt, indicating it was only a matter of time before failure occurred. By upgrading, he avoided catastrophic engine damage and experienced a slight increase in fuel mileage during a 2,300-mile trip.
- Anthony’s Ram 6.7L Failure: Anthony’s 2017 Ram 6.7L began exhibiting a faint knocking sound a week after an oil change. A month later, the engine catastrophically failed in the middle of the road. Upon inspection, the #6 cylinder was completely destroyed, with missing valves and a pulverized head. Later, after learning about the grid heater bolt issue, Anthony realized his failure matched the known problem. He installed the Banks Monster Ram to protect his rebuilt engine from future failures.
Owners who have experienced these failures often face costly repairs, extended downtime, and even require complete engine replacements. To prevent these risks, Ram owners must consider a more reliable solution.
The Banks Monster: A Game-Changing Solution
Banks has engineered a high-quality alternative to the factory grid heater, the Banks Monster-Ram Intake & Heater Grid Upgrade. This intake system replaces the restrictive stock components and eliminates the failure-prone bolt issue while also improving airflow and engine efficiency.
Key Features of the Banks Monster-Ram Intake & Heater Grid Upgrade:
- “Failure-Proof” Design: The Monster Ram system includes a high-flow billet intake plate, eliminating the stock heater assembly. Instead, it uses a high-flow Banks coil heater mounted securely into the top of the casting, ensuring no loose bolts can fall into the engine.
- Optimized Airflow and Pressure Distribution: The Monster Ram improves airflow from the intercooler, flowing 72.7 lbs/min compared to the stock’s 38.6 lbs/min—an 88.3% improvement that enhances engine efficiency and performance.
- Quicker Throttle Response and Fuel Economy: The free-flowing design increases oxygen-rich air intake, improving combustion and throttle response while also raising boost without increasing turbine drive pressure.
- Banks Coil Heater: The Banks exclusive coil heater sits vertically inside the Monster-Ram without hindering airflow. This allows the factory grid heater to be replaced with the Banks Billet Intake Plate.
Conclusion
The Dodge Ram grid heater failure is a serious issue that can lead to catastrophic engine damage and expensive repairs. The factory heater grid’s design flaw poses an unnecessary risk, but Banks has developed the solution, the Monster-Ram Intake & Heater Grid Upgrade. By upgrading to the Banks Monster Ram, these owners can eliminate the risk of failure while improving their engine’s airflow, performance, and longevity.
References:
https://official.bankspower.com/insider_news/grid-heater-crisis-averted/
https://bankspower.com/products/monster-ram-42804-ram-3500-4500-5500-cummins-chassis-cab-monster-ram#heater
https://www.xtremediesel.com/blog/2021/02/22/hot-stuff-diesel-glow-plugs-and-heater-grids/
https://official.bankspower.com/insider_news/waiting-would-have-killed-his-ram/
https://official.bankspower.com/insider_news/another-failure-on-ram-grid-heater-bolt/
https://official.bankspower.com/insider_news/grid-heater-crisis-averted/
https://official.bankspower.com/insider_news/this-is-what-ram-engine-failure-looks-like/
https://official.bankspower.com/insider_news/failure-proofing-a-ram/