BD Diesel Killer Grid Heater Kit May Kill Your Cummins Engine

Here are 6 reasons why Banks Monster-Ram is the most complete, cost-effective solution, for preventing RAM Cummins grid heater bolt failure while improving throttle response by removing airflow restrictions.

1. The Monster-Ram intake system includes a specially designed high-flow billet intake plate that replaces the factory grid heater, completely removing the failure-prone bolts with it. The factory grid heater assembly becomes an airflow killer over time. With a restrictive design from the start, it gets worse as oily soot builds up on the heating element. Nearly all diesel mechanics we’ve spoken to have experience with grid heaters so caked with soot, that they wonder how the engine is able to run. Eliminating the factory-style grid heater is the answer.

2. The BD fix does not prevent the second grid heater bolt from failing and damaging the engine. While BD claim to include a replacement bolt that is of a higher grade, there is nothing to prevent it from melting and falling into the manifold. 

The first generation of the BD kit included a nut and bolt. Shortly after we pointed out that the nut would most certainly fail, they updated the design, eliminating the nut. The bolt now threads directly into the bus bar as shown below. However, an important issue still remains. The bolt supports the bus bar and prevents it from grounding out on the body of the grid heater. The problem is that it's separated from the body of the grid heater by two insulation washers. BD has essentially repeated Cummins' originally failure point. As the grid heater shrinks and grows with heat cycles, so do the washers. Their dimensional thickness is effected. This is known as "heat set." This may lead to gap between the head of the bolt and the body. 200 amps is enough to arc, jumping across this gap. This superheated arcing is what leads to the stock threaded stud and nut deforming and failing. 

Imagine spending six hours installing the BD kit, only to have the secondary bolt fail a few years later and with the same destructive results. 

3. BD's replacement busbar (highlighted below) is nearly 0.5" wide, further restricting airflow. By impeding airflow, it promotes quicker buildup of oily soot on the grid heater. By contrast, the stock bus bar is less than .09" thick when turned on its side. Cummins did not want to further block airflow. BD made a performance-killing device.

4. From the start, the Banks Monster-Ram was developed as a performance upgrade, with or without the use of other upgrades or tuning. By removing restrictions in the stock intake air system, Monster-Ram dramatically improves throttle response by increasing air density into the manifold. This also unloads the turbo's compressor. In other words, the turbo will make the same boost with less effort.

5. RAM 6.7L Cummins ownership was once anchored in the brand’s legendary reputation for durability. Today, Cummins’ standing has eroded as more and more owners become aware of the ticking timebomb in the engine. When choosing a preventative measure, RAM owners should consider the engineering behind the product. The Monster-Ram system took more than a year to develop, taking advantage of Banks' in-house expertise in mechanical engineering and fluid dynamics. The Monster-Ram restores faith in the Cummins 6.7L engine and provides owners with peace of mind.

6. The Monster-Ram intake system and BD's Killer Grid Heater Kit both require 4-6 hours of installation time. Why wouldn't you install the system that prevents all forms of grid heater failure and improves performance?

No one wants to replace their $30,000 Cummins engine because a tiny nut and bolt fell off the factory air intake grid heater and into cylinder #6. Buying the BD kit over the Monster-Ram buys you time, but is not a complete solution nor is it proven to stand the test of time with thousands of heat cycles.