DPS High-Flow Intake Horn for 5.9 Cummins 2003-2007 | 3rd Gen Dodge Ram
The Diesel Power Source® high-flow intake horn for 2003-2007 Dodge Ram 2500 and 3500 trucks with the 5.9L common rail Cummins engine replaces the restrictive factory intake elbow with a precision-cast, CNC-machined aluminum horn that delivers smoother, less turbulent airflow into the intake manifold. This Arctic Air intake horn is designed to eliminate the sharp bends and bottlenecks in the stock intake path that restrict airflow, reduce turbo efficiency, and raise EGTs under load.
The stock 3rd gen intake horn forces air through a tight-radius curve that compresses and disrupts the airflow before it reaches the cylinder. This restriction is measurable even on stock trucks and becomes a significant bottleneck on any truck with turbo or fueling modifications. The DPS intake horn uses an elongated, oval-profile curve that maintains the cross-sectional area of the airflow path through the turn, reducing turbulence and delivering cooler, denser air to the engine.
This intake horn retains the factory heater grid without sacrificing airflow performance. It is cast from aircraft-grade aluminum, CNC machined for precise fitment, and includes four pre-tapped accessory ports.
Why the Stock Intake Horn Is a Restriction
The factory 2003-2007 5.9 Cummins intake horn uses a sharp-radius curve that creates two problems. First, air velocity increases unevenly as it rounds the tight bend, creating turbulence that disrupts the smooth flow into the intake manifold. Second, the cross-sectional area of the airflow path actually shrinks at the curve, creating a bottleneck that limits the total volume of air the turbo can push into the engine.
Many aftermarket intake horns attempt to solve this by flattening the curve, but this approach can actually make the restriction worse by reducing the internal volume at the transition point. The DPS design takes a different approach by elongating the curve and transforming the cross-section from circular to oval through the turn. This maintains the full airflow area while guiding the air smoothly through the bend with minimal turbulence. The result is more air volume, less turbulence, and cooler intake temperatures reaching the cylinders.
Performance Benefits
- Approximately 10 to 20 HP gain on stock 5.9 Cummins engines. Modified engines may see greater improvement.
- Improved throttle response from reduced intake restriction
- Faster turbo spool-up from smoother airflow path
- Lower EGTs under load from improved air density and volume
- Improved fuel economy from more efficient combustion
- Retains factory heater grid with no loss in airflow performance
Specifications
| Specification | Value |
|---|---|
| Material | Aircraft-grade cast aluminum, CNC machined |
| Design | Elongated oval-profile curve (Arctic Air design) |
| HP Gain | Approximately 10 to 20 HP (stock engine) |
| Accessory Ports | Four pre-tapped (1/8" and 1/4" NPT) |
| Heater Grid | Retained (no modification needed) |
| Fitment | 2003-2007 Dodge Ram 5.9L Cummins (3rd gen) |
| Installation | Direct replacement for stock intake horn |
What's Included
- DPS High-Flow Intake Horn (Arctic Air design, CNC machined aluminum)
- Plugs for pre-tapped accessory ports
Note: Contents may vary. Confirm included components upon receipt.
Pre-Tapped Ports
The intake horn includes four pre-tapped ports in 1/8" and 1/4" NPT sizes, ready for direct installation of aftermarket accessories. These ports can be used for boost gauges, nitrous injection, water/methanol injection nozzles, or any other accessory that requires a connection to the intake airflow path. All ports are plugged when shipped.
Key Features
- Eliminates Stock Airflow Restriction — Elongated oval curve replaces the restrictive factory sharp-bend design
- Aircraft-Grade Aluminum — Cast and CNC machined for precision fit and high boost pressure durability
- Retains Factory Heater Grid — No heater grid delete or modification required
- Four Pre-Tapped Accessory Ports — 1/8" and 1/4" NPT for gauges, nitrous, water/meth, and other accessories
- Direct Bolt-On Replacement — Replaces factory intake horn with no modification
- Reduced Turbulence — Oval-profile transition maintains full airflow area through the curve
- One of the Easiest 5.9 Cummins Performance Upgrades — Significant gains from a bolt-on part
Fitment
This intake horn fits 2003, 2004, 2005, 2006, and 2007 Dodge Ram 2500 and 3500 trucks with the 5.9L common rail Cummins engine (3rd generation). Direct replacement for the factory intake horn/elbow.
Have a 1998.5-2002 24V truck? See the DPS High-Flow Intake Horn for 24V Cummins 1998.5-2002.
Related 5.9 Cummins Products
Frequently Asked Questions
Yes. This intake horn is a direct bolt-on replacement for the factory 2003-2007 5.9L Cummins intake horn. It retains the factory heater grid and requires no modification to the engine or intake manifold. Installation is straightforward with basic hand tools.
On stock 5.9 Cummins engines, this intake horn typically adds approximately 10 to 20 HP by eliminating the airflow restriction in the factory intake horn. Modified engines with turbo and fueling upgrades may see greater improvement because the restriction becomes a larger bottleneck at higher airflow levels.
The intake horn includes four pre-tapped ports in 1/8" and 1/4" NPT sizes. These can be used for boost gauges, nitrous injection, water/methanol injection nozzles, or any other accessory that connects to the intake airflow path. All ports are plugged when shipped.
Yes. The intake horn is a bolt-on replacement that requires no tuning, no fabrication, and no other supporting modifications. It delivers measurable gains in horsepower, throttle response, turbo spool-up, and EGT reduction from a single part swap. For trucks that tow or run any level of fueling modifications, this is one of the most effective and affordable upgrades available.
1 Review
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Great product, even better price!
Great product. Can't beat the price! Definitely stands out in the engine bay. I've actually bought one for my 2nd gen and now my 3rd gen. Only issue I had was trying to put the nut on the rear driver side stud. Seems like you have to play with the height of the stud to give the nut clearance to spin on. Might have to use a dremel to make a tad more clearance. Have had the same issue on both trucks. Overall great buy. Won't be my last. Thanks
