Cummins intake heater problems. The problem is the material of these bolts.

Cummins intake heater problems 7L Cummins Grid Heater Problems. Units experiencing Fault Code 383 may have experienced extended on-time of the intake air heater with no air flow entering the system caused by a stuck relay, causing the air heater to overheat. Apr 4, 2019 · P2609 Trouble Code: RAM 6. The intake preheater only works when it is cold. 780,000 Sep 22, 2022 · In this article, we will look into the Cummins grid heater problems. 3. 7L Intake Air Heater Performance Can Lead To Engine Failure A bolt in the 2007-2023 RAM 6. Nov 14, 2024 · The intake air heater is controlled by your vehicle’s computer and continues to cycle until your engine has achieved the ideal operating temperature. Before Over time, a bolt in the 2007-current RAM 6. 7 Cummins Intake Air Heater Relocation Kit but you may not be interested as it consists of a metal ring and a new bolt for $299. Why Is the Intake Heater Indicator On but Not Activating Relay or Solenoids on My 2005 Dodge 3500 5. 7L Cummins grid heater deteriorates, falls into the intake runner, and makes its way into cylinder #6. This problem, characterized by the melting of the electrical stud and nut on the underside of the heater, has left many owners with expensive engine repairs or replacements in excess of $10,000. In many cases, this results in What Is the Cummins Grid Heater Bolt Failure? Before switching to glow plugs on 2025 model year Ram trucks, 6. Dec 5, 2010 · Replace the ambient temp sensor located right behind the grid heated on the intake cover. Dec 9, 2018 · I think you have bigger issues than intake heater problems. the web said start with the jiggle test and sure enough my Grid Heater Bolt jiggled like hell. The air intake heater used on Cummins diesel engines doesn’t come without occasional problems. 7 Cummins grid heater replacement is a solution to address common grid heater problems specific to this engine model. The bolts are Learn why grid heater issues are common in 5. Apr 7, 2023 · I just saw intake grid heater & assumed that it was for the bolt problem. If your intake air heater is not heating up and if there is no voltage drop because of the electrical load that is not placed on the intake air heater then you can potentially find your problem being an unserviceable air intake Over time, a bolt in the 2007-current stock RAM 6. 7L engine, you might be familiar with an often-discussed issue: the grid heater failure. 7 Cummins, and it’s happening at an alarming rate, enough for us to now consider it a common problem. The grid heater, also known as the intake heater, is responsible for preheating the air entering the engine for combustion. They were in contact with star to tell them how to fix and said they hadn't heard of this problem before. That should solve your problem. Jun 19, 2023 · We specialize in all Cummins diesel repairs, including Cummins intake heater problems. The bolt in the cylinder causes Jun 22, 2023 · Find the intake air heater and then find the leads to that heater. 9 Cummins? Intake air heater relay stuck closed leading to extended on-time of the heater. I’m a mechanic by trade and really wanted to do the bd diesel performance upgrade for the grid heater, but didn’t feel comfortable touching the engine while under warranty in case damage was found. 4K views 4 replies 1 participant last post by Guest Sep 7, 2013 csixer Discussion starter Oct 31, 2021 · Is the Ram 6. 7L Cummins diesel engines used a grid heater to aid cold starts. The Jan 19, 2016 · check the intake manifold air temperature sensor this sensor tells the ECM when to turn the grid heater on by what temp the intake is as i recall anything under 66 degrees it does not turn the heater on anything below 66 at start it turns it on the grid heater. In Texas the truck shouldn’t even have issues to start. Oct 30, 2025 · A deep dive into the 6. Did Ram fix the grid heater bolt failure for 5th gens? If it's still an issue, what is Dec 5, 2023 · Finally going to tackle this grid heater bolt failure before it becomes a problem. The precise cause of this failure is debated, but a major contributing factor is the 200A current flowing How common of an issue is this grid heater failure on the 6. Understanding the RAM grid heater problem RAM grid heater failure is a known issue that can lead to catastrophic damage if not addressed. 7L air intake grid heater failure which has led to significant engine damage in a growing number of RAM trucks. We will also highlight the symptoms to look out for, what causes the problem, and ways to fix the problems. I believe you may have injector issues causing your long crank time. A P2609 may be a warning. 7L intake air heater can cause severe engine damage. Feb 13, 2025 · The code is p2609- intake air heater performance. This problem, often marked by the melting of the electrical stud and nut beneath the heater, has resulted in costly engine repairs or replacements, sometimes exceeding $10,000. The "Wait to start" light still comes on but my volts never drop to around 9-10 like the heater is on. May 1, 2017 · Intake heater issues P0541 Jump to Latest 22K views 15 replies 7 participants last post by rghavana Oct 23, 2024 solerunner Discussion starter Jun 20, 2023 · The intake heater grid in Dodge Cummins trucks helps improve emissions and efficiency during cold starts. Sep 4, 2023 · A new problem has developed on the 6. Any suggestions?? Thanks Nov 23, 2023 · The fuel solenoid needs 2 wires to operate if it is internally grounded and could have three wires which would be the ground, One wire is the pull in circuit and the other wire is the hold in circuit. It can cause part of the intake air heater to fall into the engine and cause catastrophic engine damage. 7 Cummins found in the Ram 2500 and Ram 3500 trucks may experience intake air heater failure. This is apparently a thing, that I've just very expensively found out about. Mar 11, 2023 · Yep, Intake heater problem. I read about the grid heater bolt issue. 9L Cummins engines. 7L Grid Heater Failure & Prevent Costly Damage The Problem If you own a Cummins 6. From heat and deterioration the bolt has a tendency to fall off, which then sends it through the intake manifold where it winds up inside cylinder #6. 7? : r/Cummins r/Cummins Current search is within r/Cummins Remove r/Cummins filter and expand search to all of Reddit Nov 9, 2022 · 2013 2500 purchased new, 140K miles So - I'm late to the party. Has anyone had any experience with either of these or possibly another way to fix it?. The problem starts in the electrical connection to the intake grid heater. 99 2500, Quad cab, 4x4 47RE, BD pressure lock on it, small BD 90/140 chip on the VP 44 connection plug, 17" 3rd gen wheels. Man with all of the issues that arise on these HD's, you would think they just came out with a new model this year. 5-2022 6. 7L grid heater bolt. 7L engine, you might be all too aware of a common issue: grid heater failure. The isolated power connection bar may expand and lift from the top surface of the intake manifold cover due to extended Oct 30, 2025 · How to Fix Cummins 6. Mar 5, 2025 · A history of the well-documented Cummins 6. Jan 10, 2025 · There seems to be 2 options for fixing it, the Banks Monster Ram intake and Grid Heater Upgrade or the BD Killer Grid Heater Upgrade. Diagnose failures and discover how SPELAB’s intake upgrade boosts airflow and performance. Dec 12, 2020 · Has anyone else had an issue with the nut coming off the grid heater and going in to the motor. 3 mechanical it would fire up after the first cylinder hit top dead center and when the Jun 19, 2023 · There is one solution and it is called the 2007. For those of you who don't know, the battery harness that hooks to your grid heater gets so hot it melts through the bolt sending the nut through your valve and into your #6 cylinder destroying your piston, valves and Sep 25, 2020 · Use the grid heater to save yourself then unplug when you get where you need to be (could you just hold the cable on the terminal or is that asking to die??) 2) Do what I’m going to do when Banks releases their new monster ram intake horn for EGR trucks an put a throttle valve grid heater on instead! Mar 31, 2010 · For some reason all of a sudden my intake heater is not working? Very hard to get the truck to start. Found the grid heater and relay bad and to receive them today. 7 Cummins engine reliable? Read about 6 common problems such as clogged DPF filters, EGR cooler and turbo failure, and more. Unplug the sensor and take your intake horn off and turn the key on for a few second. Chewed up a piston and took some chunks of out of the head. Sep 15, 2023 · Hey everyone, New to the Ram world. Dec 27, 2024 · What Is The Grid Heater Bolt Issue? The grid heater, the intake air heater, warms incoming air for easier cold-weather starts. If you're reading this article, you may have come across this topic from a forum or Gale Banks' Video outlining the issues involved with this seemingly harmless bolt that gives power to the grid heater for cold starts. Troubleshooting intake heater issues involves a systematic process of inspection, testing, and repair. Ruenell front bumper and warn winch, Rancho adj shocks. Be careful not to tear it or you will be getting a new one of those too. 55 diffs. I live in ND and it’s crucial for the grid heater to work to get the truck started in winter but with the air intake temp sensor reading around 80 degrees it’s not allowing the grid heater to work. 7L Cummins grid heater is loose. Sep 18, 2015 · Are the insulators missing a the connections to he heaters? PS there are no grounds on the heater grids, they ground directly to the intake horn. Watch out with the intake gasket. Heater bolt sucked into intake and danced the two step with my head and a cylinder. Learn the symptoms (P2609), affected years, recall confusion, and solutions from delete kits to Banks & BD Diesel upgrades. In many cases, this Mar 18, 2025 · Ram and Cummins finally kicked the grid heater for 2025 model-year trucks, and while you might think it’s a reliability decision, they say it’s for a different reason. I have replaced the AIT sensor no Sep 6, 2013 · February's Cummins of the Month is now open for entries! intake heater problem Jump to Latest 2. You can check Youtube on how to do it. Fca has three different bulletins out 2 from 2016 and one from this year and they won't even do anything to help cover the cost of a new motor Jun 4, 2025 · The Problem If you own a Cummins 6. I took the grid right out of my truck and it fires off easily in single digit temps, it’s not happy about it but it fires off none the less. 7L Cummins stock grid heater deteriorates, falls into the intake runner, and thanks to gravity, makes its way into cylinder #6. In this system, a grid heater plate is bolted to the intake manifold and secured with the bolts. 7 Cummins grid heater bolt failure. The factory grid heater has a bolt and stud on the bottom side of it. I did the ‘jiggle test’ on the the grid heater connection and it is very loose. My truck basically tows a 25-30k trailer all day everyday so if I can get a performance upgrade out of it that'd be great too. Jul 10, 2023 · Over time, a bolt in the 2007-current RAM 6. Disconnect the leads and check for resistance at those leads. I do still need some kind of an intake heater though because in the winter it does get Jun 19, 2023 · The 6. Learn how to prevent failure. Jul 17, 2019 · Grid heater failure 2019 Ram 3500 big horn with 3500 miles, on July 9th had the same problem, dealer replaced alternator and batteries then went dead and ruined 2 more batteries. Aug 29, 2020 · This guy speaks of one of the flaws of the CTD, the "heater grid bolt" that rots, comes loose, goes down the intake into the # 6 cylinder and causes Jun 4, 2024 · The 6. Read on to learn how the Banks Monster-Ram can prevent it. Over time, they can loosen, shear, or break due to many heat cycles, the engine's vibrations, or simply corrosion. I just did some searching on here and it appears the grid heater bolt failure is an issue for later 3rd gen and 4th gen trucks. Over time, a bolt in the 2007-2024 RAM 6. In short, the component warms intake air with an electrical heating element. When I had an 8. In many cases, it results in total engine Mar 30, 2023 · Is your Cummins RAM truck experiencing issues such as overheating, engine failure, or transmission problems? Learn how to file a claim. If the post jiggles, it indicates that the nut and bolt To learn more about RAM grid heater failure and watch videos of those affected by the failure, see our in-depth article, P2609 and P0542 Codes | Avoid RAM 6. If it starts generating heat at the grid heater then you know that your grid Here's how you test to see if the nut and bolt in your factory RAM 6. I have a 2016 2500 and this just happened to mine. I don't know what temperature it comes on. The 6. The problem is the material of these bolts. Dec 27, 2020 · I have an 05 that I cannot get the air intake temp working on. 2r3rf jgkmfbv 1yy v9a7avvo yyc b6ubkx 10j5hk hu6 ybn 6vc0k

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