The Problem

If you own a Cummins 6.7L engine, you might be familiar with an often-discussed issue: the grid heater failure. 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. The exact cause of this failure is debated, but a significant factor is the 200A current running through a ¼” stud to the heater. Over time, heat cycling and vibration can loosen the bolt, leading to arcing and accelerated failure of the connection. Worse yet, the nut from this nut stud can fall into the intake runner and make its way into cylinder #6, causing severe piston, valve and head damage or total engine failure.

The Solution: Introducing BD’s Innovative Killer Grid Heater Upgrade Kit

To tackle this common issue, we developed an innovative solution that upgrades the entire power path to the heater, eliminating the problematic nut and stud in the intake. This kit replaces the stud with an M8 bolt fastened through the top of the grid heater, providing a reliable and robust connection.

Our grid heater upgrade kit is designed to address the critical issue of grid heater failure in Cummins 6.7L engines. This failure often leads to engine damage or failure, but with our kit, you no longer need to worry about the grid heater bolt melting off and being ingested by the engine. This inexpensive and easy-to-install solution maintains full stock heater output, requires no tuning, and is fully emissions-compliant. By securing the busbar from the outside through the top, this simple yet effective solution provides peace of mind for Cummins owners.

Key Features

  • Eliminates the risky Grid Heater Stud and Nut: By removing the problematic stud and nut from the intake, our kit prevents the risk of these parts melting off and entering cylinder 6, potentially causing catastrophic engine damage or failure.
  • Full Heater Output Without Worry: Our solution allows the grid heater to operate at full power (2400W) without the risk associated with the original setup, unlike the 600W coil heaters or disconnecting the heater entirely.
  • No Engine Codes or Tuning Required: You won't face any P2609 (Low grid heater current) codes or need to perform any ECM tuning with our kit.
  • Self-Locking Threads: The lower busbar features Emuge self-locking threads, ensuring that the bolt remains securely fastened, even through heat cycling and vibration.
  • Simple and Quick Installation:
    The installation process is similar to a grid plate replacement and takes only about an additional 30 minutes. No modifications or tuning are necessary.
    • Cost-Effective Solution: Our kit is much more affordable compared to alternatives like open grid plates, external coil heaters, or aftermarket intake horns.
    • Comprehensive Kit: Comes with all new replacement installation hardware.
    • Corrosion-Resistant: The upper copper busbar is tin-plated, and the lower steel busbar is zinc-plated to combat corrosion.

    The weak point of the original grid heater—specifically, the ¼” stud and nut—has been replaced with a robust M8 bolt that threads through the top of the grid plate into a tapped busbar. This change almost doubles the cross-sectional area of the connection, reducing electrical resistivity and minimizing heat. The top-down secured busbar eliminates the presence of internal hardware that could enter the engine upon failure. The lower busbar’s Emuge self-locking threads prevent bolt loosening due to heat cycling and vibration. Additionally, the plastic parts are made of glass-filled nylon, ensuring electrical insulation and mechanical stability at high temperatures. The installation is straightforward, requiring minimal additional time beyond removing the intake horn and grid heater plate.

    Product Benefits

    Our grid heater upgrade kit significantly improves the lives of Cummins 6.7L owners by eliminating the fear of grid heater failure and potential engine damage. This solution negates the need for expensive intake horn replacements or the use of undersized coil heaters. It ensures reliable cold weather starts and maintains heating efficiency close to the engine, unlike coil heaters that are placed further away. 

    Ideal Customers

    Our product is perfect for all 6.7L Cummins owners who want to easily prevent a catastrophic engine failure. It's a cost-effective solution for those seeking reliability and peace of mind rather than performance enhancements. It’s especially beneficial for those living in cold climates who rely on an intake heater for starting their truck, increasing fuel efficiency, and reducing emissions with full heater output. Additionally, it’s suitable for customers in areas with emissions testing. Our kit is ideal for customers who want to avoid ECM tuning or check engine lights after disconnecting the stock grid heater.