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Cummins platform

Cummins 5.9L Diesel (Dodge Ram HD)

1994-2007 · 5.9L · Cummins Inc.

28
vehicle configs
10
failure modes
24
parts
4
recipes
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Failure modes

53-block casting crack (24v ISB)
APPS (throttle position sensor) failure / dead pedal (24v)
Common-rail injector wear / nozzle carbon (03-07)
Intake grid heater / relay failures (cold starts)
Head gasket failure on tuned common-rail trucks (03-07)
Killer Dowel Pin (KDP) on the 12v P-pump engines
Fuel lift (transfer) pump failures
12v overflow valve weak (hard start / low power)
Turbo wastegate actuator seize / boost control (HX35W, HE351CW)
VP44 injection pump death (24v ISB)

Parts

5.9L Cummins Throttle Position Sensor / APPS (XDP) part-c59-apps-tps 5.9L Cummins 24v Cylinder Head, remanufactured (Fleece Freedom Series Street HD, 1998.5-2002) part-c59-cylinder-head-24v 5.9L Cummins Reman Long Block (2003-2007) part-c59-engine-long-block 5.9L Cummins Fuel Pressure Gauge (Isspro / PPE) part-c59-fuel-pressure-gauge cummins-5_9: engine-gasket-set (honest catalog gap) part-c59-gasket-set-gap 5.9L Cummins Billet Grid Heater Replacement (1/2-inch taller) part-c59-grid-heater-billet 5.9L Cummins Head Gasket Set, 12v (PSP MLS, 89-98) part-c59-head-gasket-set-12v 5.9L Cummins Head Gasket Set, 24v (PSP MLS, 98.5-02) part-c59-head-gasket-set-24v 5.9L Cummins Head Gasket Set, common-rail (Mahle / Fire Ring, 03-07) part-c59-head-gasket-set-cr 5.9L Cummins Main Stud Kit (P1, 24v common-rail) part-c59-head-stud-kit cummins-5_9: injector-seal-kit (honest catalog gap) part-c59-inj-seal-gap 5.9L Cummins Common-Rail Injectors, early build (S&S, 2003-2004.5) part-c59-injector-cr-early 5.9L Cummins Common-Rail Injectors, late build (S&S, 2004.5-2007) part-c59-injector-cr-late 5.9L Cummins Killer Dowel Pin Tab Kit (Power Driven) part-c59-kdp-tab-kit 5.9L Cummins Fuel Lift Pump, 12v (Alliant Power) part-c59-lift-pump-12v 5.9L Cummins Lift Pump, 24v Direct Replacement (FASS DRP02) part-c59-lift-pump-24v-drp02 5.9L Cummins Lift Pump, 03-04.5 Direct Replacement (FASS DRP04) part-c59-lift-pump-cr-drp04 5.9L Cummins Mechanical Lift Pump Kit (Waterman, upgrade) part-c59-lift-pump-cr-upgrade 5.9L Cummins Lift Pump Relocation Kit for FASS DRP02 (FASS RK02) part-c59-lift-pump-relocation-kit 5.9L Cummins Overflow Valve, P7100 12v (Dynomite Diesel) part-c59-overflow-valve 5.9L Cummins Turbocharger HX35W (PurePower new / Holset) part-c59-turbo-hx35w 5.9L Cummins Injection Pump VP44 (XDP remanufactured) part-c59-vp44 5.9L Cummins Water Pump (Diesel Site cast iron / XDP Xtra Cool) part-c59-water-pump cummins-5_9: turbo-actuator (honest catalog gap) part-c59-wg-actuator-gap

Recipes

Common-rail injector replacement for 2003-2007 trucks (mode fm-c59-cr-injector-wear): worn nozzles and copper-seal blow-by ('chuffing')
Fuel supply health across all three 5.9 generations (mode fm-c59-lift-pump-failure): every electric frame pump on these trucks is a consumable, and 2005+ moved it in-tank
Killer Dowel Pin (KDP) prevention for the 12v P-pump engines (mode fm-c59-kdp-dowel-pin): the dowel pin that locates the front cover can back out and drop into the gear case
VP44 death cascade repair for 1998.5-2002 24v trucks (mode fm-c59-vp44-failure)

From the blog

HistoryCummins 5.9L Diesel

How a Tractor Engine Ended Up in a Dodge: The 5.9 Cummins Story, 1989-2007

· 5 min read
Problem explainerCummins 5.9L Diesel

5.9 Cummins VP44 Failure: Symptoms, the Lift Pump Connection and What to Check First (1998.5-2002)

· 10 min read
Buyer's guideCummins 5.9L Diesel

Buying a Used 5.9 Cummins: 12-Valve, 24-Valve or Common Rail, and What Each One Breaks

· 12 min read

Vehicle configurations