RAM 6.7L Cummins Grid Heater Failure

Understand and Avoid RAM 6.7L Cummins Grid Heater Problem

The RAM 6.7L Cummins grid heater failure is a significant concern for truck owners, as this component is designed to aid cold starts by preheating the intake air. However, a common issue with the grid heater bolt can lead to severe engine damage, a problem that has been reported across various model years. This has caused frustration and costly repairs for many owners.

The Problem Unveiled

Grid heater bolt failure occurs when a small nut and bolt from the grid heater assembly deteriorate and fall into the intake manifold. This bolt can then travel past the intake valve into cylinder #6, embedding itself into the piston. The result is often catastrophic engine damage, including severe piston, valve, and head damage.

A Real-Life Example of Grid Heater Failure

In one notable case, a truck owner experienced a significant repair bill due to this issue. The grid heater failed, leading to a bolt embedding into the piston of cylinder #6. The repair bill amounted to over $6,400, which, while substantial, was less than the costs faced by some others, which can exceed $30,000 for a full engine replacement. To prevent future failures, the owner upgraded to a high-performance intake elbow, enhancing both performance and reliability.

Diagnosing Grid Heater Issues

Key Trouble Codes

1. P2609 Code: This code indicates a problem with the intake air heater system voltage or performance. It suggests that the grid heater bolt is failing or has lost its ability to conduct current effectively.
2. P0542 Code: This code shows that the Powertrain Control Module (PCM) has detected abnormal voltage readings from the intake air heater circuit. This could be due to corroded connectors, an open circuit, or high resistance in the heater relay.

Both codes signal potential grid heater issues and should prompt immediate inspection to avoid further damage.

How to Identify and Prevent RAM 6.7L Cummins grid heater failure

Visual Inspection: Look at the bottom of the factory grid heater. You'll find a bolt and nut assembly. Over time, this assembly can deteriorate, causing the bolt to fall into the intake runner.

Jiggle Test: Check for significant movement in the plastic post of the grid heater. If there is noticeable movement, it indicates a potential problem. Do not drive the truck; instead, tow it to a mechanic for proper inspection.

Regular Maintenance: Regularly inspect and maintain the grid heater system to prevent bolt failure. Address any symptoms of starting issues or unusual noises promptly.

Upgrading to Prevent Future Failures

High-Performance Intake Elbow

To mitigate the risk of grid heater failure and improve engine performance, consider upgrading to a high-performance intake elbow. Here's why it's a superior choice:

• Enhanced Air Flow: The upgraded intake elbow provides a significant increase in air mass flow compared to the stock unit, resulting in better throttle response and fuel economy.
• Improved Design: The intake elbow features a proprietary design that eliminates obstructions and enhances airflow.
• High-Flow Intake Plate: The system includes a high-flow intake plate that replaces the restrictive stock grid heater. This, combined with a coil heater, aids in cold starts and prevents grid heater failure.
• Emissions Compliance: The high-performance intake elbow is compliant with emissions regulations across all 50 states, making it a reliable and legal upgrade.