How to Install Air Intake on a 2002–2008 Dodge Ram 1500 (3.7L 4.7L)

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How to Install Air Intake on a 2002–2008 Dodge Ram 1500 (3.7L 4.7L)

How to Install a Dual Air Intake on a 2002–2007 Dodge Ram 1500 (3.7L & 4.7L)

The 3.7L V6 and 4.7L V8 PowerTech engines found in the 2002–2007 Dodge Ram 1500 are reliable workhorses, but the factory intake design leaves a lot to be desired. The stock setup features a large, baffled plastic resonator box (often called the "hat") that sits directly on top of the throttle body. Not only does this restrict airflow to keep the engine quiet, but as these trucks age, the plastic becomes brittle and is prone to cracking, which can cause vacuum leaks.

Swapping this out for a Dual Cone Air Intake System is a straightforward job that opens up the airflow. You will immediately notice a deeper induction tone and sharper throttle response.

This guide covers the installation process step-by-step. This is a beginner-to-intermediate job that takes about 45–60 minutes.

Tool List

Before you pop the hood, grab these tools:

  • Ratchet and Socket Set: You specifically need a 10mm socket (deep well is helpful) and a 13mm socket.
  • Flathead Screwdriver: For loosening hose clamps.
  • Nut Driver (5/16" or 8mm): Optional, but makes dealing with hose clamps much faster than a screwdriver.
  • 10mm Wrench: For the battery terminal.
  • Panel Popper or Pliers: To remove the breather hose clamp.

Phase 1: Removing the Factory System

Safety First: Ensure the engine is cool. You will be working near the exhaust manifolds and alternator.

Step 1: Disconnect the Battery

Use your 10mm wrench to disconnect the Negative (-) battery terminal. This is standard safety, but it also forces the ECU (engine computer) to reset. When you reconnect it later, the computer will begin relearning the fuel trims for the increased airflow.

Step 2: Remove the IAT Sensor

Locate the Intake Air Temperature (IAT) sensor. On these engines, it is plugged into the plastic intake tube or the resonator box near the throttle body.

Action: Unplug the wiring harness. Then, carefully twist and pull the sensor out of the rubber grommet.

Warning: Be extremely gentle with the IAT sensor. The plastic tip is fragile. You will need to reuse this sensor for the new intake.

Step 3: Disconnect the Breather Hose

Find the crankcase vent hose. This connects the oil filler neck (on the passenger side valve cover) to the back of the factory airbox/resonator. Use pliers to slide the clamp back and pull the hose free from the airbox.

Step 4: Remove the Resonator "Hat"

The large black box sitting on top of the engine is held in place by a clamp and two bolts.

  1. Loosen the hose clamp connecting the box to the throttle body using a flathead screwdriver or nut driver.
  2. Locate the two 10mm bolts on the front of the resonator box (near the alternator and AC compressor). Remove these bolts.
  3. Lift the resonator box up and off the throttle body.

Step 5: Remove the Air Filter Housing

The rest of the airbox (where the square filter sits) is located on the passenger fender. It is usually held in place by rubber grommets. Firmly pull the box straight up to pop the pins out of the grommets. Remove the entire assembly from the truck.

Phase 2: Installing the New Dual Intake

Step 1: Prepare the New Tube

Before putting the new aluminum tube on the truck, get the components ready.

  • IAT Sensor: Install the supplied rubber grommet into the hole on the new intake pipe. Carefully push your factory IAT sensor into this grommet.
  • Breather Fitting: If your new pipe has a threaded hole for the vent hose, screw in the supplied barbed fitting now.
Pro Tip: Use a tiny dab of dish soap or silicone spray on the rubber grommet. This helps the delicate IAT sensor slide in without breaking.

Step 2: Install the Throttle Body Coupler

Place the silicone coupler (reducer) onto the engine's throttle body. Slide a hose clamp over it and tighten it down snug at the throttle body side. Leave the top clamp loose for now.

Step 3: Install the Main Tube

Insert the main intake tube into the silicone coupler. Do not tighten the clamp yet. You need to be able to rotate the tube to get the filters to sit level.

Step 4: Reconnect Lines

  • Crankcase Vent: Connect the hose from the oil fill neck to the nipple/fitting on your new intake tube. Secure it with the provided small hose clamp.
  • IAT Harness: Plug the electrical connector back into the IAT sensor. Ensure the wire has enough slack; if it's tight, rotate the intake tube slightly to bring the sensor closer to the harness.

Step 5: Install the Dual Filters

This is the signature look of this kit.

  1. Slide the large hose clamps onto the flanges of the two cone filters.
  2. Install one filter onto each end of the "T" pipe.
  3. Adjust the filters so they are symmetrical and not rubbing against the hood insulation or the AC lines.
  4. Tighten the filter clamps.

Step 6: Final Tightening

Once everything is aligned perfectly:

  • Tighten the main clamp at the throttle body coupler.
  • Double-check the IAT sensor is seated fully.
  • Ensure the breather hose is secure.

Phase 3: The First Start

Reconnect your negative battery terminal. Double-check that you haven't left any tools in the engine bay (check the cowl area especially).

Start the engine. It is normal for the idle to fluctuate slightly for the first minute as the ECU adjusts to the new airflow. Listen for a high-pitched whistle—if you hear one, it usually means the coupler at the throttle body isn't tight enough.

Maintenance Note: The filters in this kit are reusable. We recommend checking the clamps after 100 miles of driving to ensure nothing has settled or vibrated loose. Clean and re-oil the filters every 15,000 to 20,000 miles.