Banks Intercooler

What is an intercooler?

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The intercooler is the part of the engine set up that sits between the turbocharger and the engine. It is usually situated near the front of the vehicle behind the radiator grille so that it can benefit from the incoming and cooler ambient air. An intercooler’s primary responsibility is to increase the air density of the air going into the engine.  z

Why is the intercooler important? 

If your vehicle has a turbocharger then having a properly functioning intercooler is a must for proper engine performance. A turbocharger’s job is to compress the air, which builds pressure and enables the engine to get a powerful boost as the pressurized air is pushed into the engine. However, the downside of using a turbocharger by itself is that the process of compressing the air creates a lot of heat. Exhaust gasses, which can be extremely hot, are often combined with the air in the compressor as well, making the resulting temperature of the compressed air too high to provide the necessary oxygen to create a significant gain in horsepower.

How does an intercooler work?

There are two main kinds of intercoolers: Air-to-Air intercoolers and Air-to-Water intercoolers. Banks Intercooler products are air to air intercoolers so that is the type that we will focus on.

Air-to-air intercoolers are classified as an intercooler that uses ambient air to lower the temperature of the air traveling through the intercooler. This is accomplished through heat exchange. The intercooler separates the air into different tubes that are connected to fins or coils that conduct the heat out of the contained air and into the ambient air. As ambient air passes through the radiator grille it also passes between the fins or coils and pulls heat from them, enabling them to pull more heat from the contained air. 

Once the air reaches the end of the path it is brought back together in the exhaust chamber where it combines again, and is pushed through the boost tube into the intake manifold. The air that passes through the intercooler becomes denser air with a higher concentration of oxygen. It makes for a more regulated combustion that is better for the vehicle’s performance and health.

Why is the Banks intercooler called an upgrade?

The term “upgrade” means to “raise something to a higher standard.” This is exactly what Banks Power has done with their intercooler.

In their drive to build aftermarket components that truly enhance the performance of diesel engines, Banks Power keeps their focus on air density. Air density, or the amount of oxygen available in the air, is what indicates how much power a combustion engine is able to produce. There are only two components that add to air density: the intercooler and the turbocharger. Every other engine component reduces the air density, so it is important to capitalize on what the turbocharger and the intercooler can do. 

The Banks Intercooler is designed to keep the air density provided by the turbocharger and increase it to the fullest amount possible. Let’s take a look from start to finish on just how different these intercoolers are from the competition.

Banks Boost Tubes

Intercoolers connect to the turbo and the intake manifold using pipes known as boost tubes. The Banks intercooler also uses boost tubes, but the design has been improved to maximize airflow. 

For starters, the size of the Banks Boost Tubes are larger than both stock and competitors by as much as an inch in diameter, and that diameter stays constant through the entire tube thanks to a process called “mandrel bending.” 

Mandrel bending is also key to eliminating sharp corners caused by other forms of bending and welding which cause turbulence. Turbulence limits the airflow, and by removing the causes of it Banks Power has been able to manufacture boost tubes to be literally turbulent free. Thanks to their fluid design and larger diameter, Banks Boost Tubes greatly outperform stock boost tubes.

As a comparison, the CFM (cubic feet per minute of airflow) in the Banks Boost Tube is up to 490 CFM while stock is around 388 CFM on the hot side, and on the cold side we have up to 635 CFM when compared to stock’s 435 CFM. That's a large difference in air density.

Another thing that makes Banks Boost Tubes better than stock components is that Banks Power makes their boost tubes out of high-quality aluminized steel. Stock parts use inferior-quality metals and flimsy plastics which may wear out or break. Aluminized steel, on the other hand, is durable, and resistant to corrosion and heat damage.

The Banks Intercooler

The engineers at Banks Power carefully study out the deficiencies of stock intercoolers and make upgrades and improvements to the complete intercooler system. Each model is a little bit different because it was designed for a specific vehicle; however, the end result with each is the same: a superior intercooler that does wonders for your horsepower. 

Banks Intercooler VS Stock

The Banks Intercooler is designed to surpass its stock counterpart in every way. 

Size/Airflow

The Banks Intercooler (also called the Banks Techni Cooler) designed for your diesel is going to give your engine more air flow and increased air density over stock. It is designed with a thicker core that provides up to 25% more flow volume. One limiting factor in making intercoolers is that you have to work within a certain range of size, otherwise it becomes cumbersome and loses its efficacy. Banks Power designs their intercoolers to make use of all the available space, giving the intercooler the maximum capacity for airflow without being too big or cumbersome.

Superior Quality

The Banks Intercooler has three main sections: the intake chamber, the exhaust chamber, and the access tubes that connect the two. Both tanks are custom-machined from cast aluminum. Stock intercoolers also have two tank ends, but one of them tends to be made from plastic. This a poor design, because plastic has a tendency to warp from heat, and can burst under the stress of the turbo. Having two durable end tanks that are made to withstand the intense pressures and temperatures associated with turbocharged air, ensures that your engine is going to function better. Additionally, the Banks Intercooler end tanks are larger, so they support increased airflow.

Banks’ Computational Fluid Dynamics (CFD) designed, rugged cast aluminum end tanks on the Techni-Cooler ensure durability and slick air flow. The same can’t be said for welded-up sheet tanks. Air doesn’t flow well with square corners, and the welds break at high boost when performance is needed the most.

Performance Benefits

The Banks Intercooler outperforms the stock intercooler on its ability to deliver cooler, denser air to the engine. However, as cool as that sounds, you can actually see the difference that these intercoolers can make for your engine performance in a few key areas. The first area is the EGTs. By monitoring your EGTs before and after you replace your intercooler, you can see that the temperature of the exhaust gasses is drastically reduced. Reducing EGTs is a great way to protect your engine.

The second benefit that can be seen when using a Banks Intercooler is the improved engine performance. Better, more consistent horsepower and torque are possible when proper, cooler air is provided to the engine. Having consistent power improves engine efficiency which translates into better fuel economy. This also protects your engine from misfires caused by insufficient oxygen in the combustion chamber.

Key Features

• Extensively tested & validated by Banks Engineering

• Large, streamlined end tanks optimize airflow and air density

• Thicker core areas for significantly more air volume

• Wide-open inlets and outlets

• Improves cooling for higher continuous power & lower EGT

• Most kits include High-flow boost tubes

• Steady power output even under extreme temperatures

• Denser air charge improves the combustion process for greater engine efficiency & better fuel economy

• Complete kits include all hardware necessary for installation

• Some kits includes a High-Ram intake manifold

Duramax

The Duramax 6.6L was first produced back in 2001 and has gone through various updates and modifications to match the changing emissions standards. Getting a Banks Intercooler for your Duramax 6.6L engines is a great upgrade. For the 2001-2004 LB7 versions of the engine the intercooler provides a nearly 95% increase in air density. For years  2005-present the intercoolers provide a 34% increase to flow volume over stock. 

 

Duramax LB7 6.6L

Banks 25976 Intercooler for 2001 Chevy Silverado & GMC Sierra 6.6L Duramax LB7

Banks 25977 Intercooler for 2002-2004 Chevy Silverado & GMC Sierra 6.6L Duramax LB7

Duramax LLY 6.6L

Banks 25978 Intercooler for 2004.5-2005 Chevy Silverado & GMC Sierra 6.6L Duramax LLY

Duramax LBZ and LMM 6.6L

Banks 25982 Intercooler for 2006-2010 Chevy Silverado & GMC Sierra 6.6L Duramax LBZ & LMM

Duramax LML 6.6L

Banks 25988 Intercooler for 2012-2016 Chevy Silverado & GMC Sierra 6.6L Duramax LML

Cummins

The Banks Intercooler series for Cummins engine provides increased airflow to boost power, performance, fuel economy. For Cummins 5.9L engines the intercooler upgrade can add an additional 27% percent airflow, and for the later 6.7L series it can provide an addtional 34%.

Cummins 5.9L

Banks 25980 Intercooler for 2003-2005 Dodge Ram 2500 & 3500 5.9L Cummins

Banks 25981 Intercooler for 2006-2007 Dodge Ram 2500 & 3500 5.9L Cummins

 

Cummins 6.7L

Banks 25987 Intercooler with Red Boost Tubes for 2013-2018 Ram 2500 & 3500 6.7L Cummins

Banks 25989 Intercooler with Boost Tubes for 2013-2018 Ram 2500 & 3500 6.7L Cummins

Banks 25983 Intercooler for 2007.5-2008 Dodge Ram 2500 & 3500 6.7L Cummins

Banks 25985 Intercooler for 2009 Dodge Ram 2500 & 3500 6.7L Cummins

Powerstroke

Powerstroke was known for having one of the largest engines back in the 90's but they cut back on their engine size in the 2000's from 7.3L to 6.0L to be more compatible with the new emissions standards, and focus on power output.  The Banks Intercooler series for the Powerstroke engine provides increased airflow in the 1994-2003 7.3L by 18%, the 2003-2007 6.0L by 21%, and 14% in the 2008-2010 6.4L.

Powerstroke F-250 & F-350 7.3L

Banks 25971 Intercooler for 1999.5 (Early-With Intake Heater) Ford F-250 & F-350 7.3L Powerstroke

Banks 25972 Intercooler for 1999 (Early - Without Intake Heater) Ford F-250 & F-350 7.3L Powerstroke

Banks 25970 Intercooler for 1994-1997 Ford F-250 & F-350 7.3L Powerstroke

Banks 25973 Intercooler for 1999.5 (Late) - 2003 Ford F-250 & F-350 7.3L Powerstroke

Powerstroke 6.0L

Banks 25974 Intercooler for 2003-2004 Ford F-250 & F-350 6.0L Powerstroke

Banks 25975 Intercooler for 2005-2007 Ford F-250 & F-350 6.0L Powerstroke

Powerstroke 6.4L

Banks 25984 Intercooler for 2008-2010 Ford F-250 & F-350 6.4L Powerstroke