2015 Product
BD 2015-2016 Fall Catalog

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Xtruded Charge Air Coolers
2003-2007 Dodge 5.9L
2003-2007 Dodge 5.9L
2010-2012 6.7L
1994-2002 2nd Gen
MICRO Extruded Tube Design
Cast end tanks with struts

A Breath of Fresh Air...

BD’s free flowing Charge Air Cooler (CAC) - or intercooler - design 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.

**Other’s Stuffed Tube CAC


Stuffed Tube designs are commonly used on stock applications with boost pressures of 20-40 psi and 200-300 OF 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.

(**Others - You know who you are!!!)

BD’ s Micro Extruded Tube CAC

Micro Extruded Tube design is for applications producing 20-100 psi of boost pressure and inlet temperatures of 500+OF. 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.

Higher turbo boost pressures results in lower EGT’s.

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 fl ow through the CAC and the higher the turbo boost pressure will result in lower exhaust gas temperatures (EGT). BD’s Xtruded CAC’s are designed for performance diesel engines.

Product Warranty 1-Year Parts
  • Available Makes
  • Dodge
  • Available Engines
  • 2007 - 2012 6.7L
  • 2003 - 2007 5.9L CR
  • 1998 - 2002 5.9L 24-Valve
  • 1994 - 1998 5.9L 12-Valve
  • Available Transmissions
  • Automatic
  • Manual
Product Rating
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    Installation: 3 points
    Performance: 3 points

1042520     1994-2002 5.9L
1042525     2003-2009 5.9L/6.7L
1042530     2010-2012 6.7L