Join Date: Oct 2017
Location: NE Washington
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Oil in the intercooler? That's usually caused by blown turbo seals. If still running the old turbo, have you checked the turbo for oil leaks? Also check shaft play. A little radial play is OK but shouldn't contact housing. Should be little to no axial play (in and out.) Oil would most likely burn off as blue smoke. I would have flushed the intercooler before reinstalling. Not hard hard to pull it off and flush it after the fact.
I would also double check to make sure you got the right injectors with the right spray patterns for your 05. Try the search function for several threads on the topic. Spray pattern and piston bowls changed between the 04 and 04.5 model years.
05 Ram 3500, SLT Bighorn, SB QC, Dynamic Stage 3 48RE, triple disc, billet input, S&B CAI, FASS Titanium, Smarty Jr., New stock Bosch injectors, Edge CTS, Hushpower/Magnaflow 4 inch, FTE Resonator, Bilstein 5100's, Redhead Steering, Truxedo, Linex