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2004 Dodge Ram 2500

Reliability tier: verified - see /disclosure/

Engine: 5.9L ISB common rail (Cummins, 5.9L)

Applicable failure modes (5)

• 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)
• Fuel lift (transfer) pump failures
• Turbo wastegate actuator seize / boost control (HX35W, HE351CW)

Applicable parts (14)

• 5.9L Cummins Throttle Position Sensor / APPS (XDP)
• 5.9L Cummins Reman Long Block (2003-2007)
• 5.9L Cummins Fuel Pressure Gauge (Isspro / PPE)
• cummins-5_9: engine-gasket-set (honest catalog gap)
• 5.9L Cummins Billet Grid Heater Replacement (1/2-inch taller)
• 5.9L Cummins Head Gasket Set, common-rail (Mahle / Fire Ring, 03-07)
• 5.9L Cummins Main Stud Kit (P1, 24v common-rail)
• cummins-5_9: injector-seal-kit (honest catalog gap)
• 5.9L Cummins Common-Rail Injectors, early build (S&S, 2003-2004.5)
• 5.9L Cummins Common-Rail Injectors, late build (S&S, 2004.5-2007)
• 5.9L Cummins Lift Pump, 03-04.5 Direct Replacement (FASS DRP04)
• 5.9L Cummins Mechanical Lift Pump Kit (Waterman, upgrade)
• 5.9L Cummins Water Pump (Diesel Site cast iron / XDP Xtra Cool)
• cummins-5_9: turbo-actuator (honest catalog gap)

Platform recipes (4)

• 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)