Halfway through the 2004 production year Cummins made improvements to the common-rail 5.9L Cummins-powered trucks. Dodge continued to incorporate their modernized big-rig body styles on the Ram pickup trucks. In 2006 the Ram trucks received new body styles and redesigned headlights. The “Mega Cab” option that offered almost 2 ft of extra cab space was also introduced. The solenoid-activated fuel injectors and engine pistons were redesigned to create a more efficient combustion. A new turbocharger was mated to the 2004.5-2007 common-rail Cummins engine that utilized journal bearings and a wastegate to bleed off excess boost pressure. The updated common-rail 5.9L Cummins was more efficient and some of the updates to the engine also provided increased horsepower and torque.
The gray-iron block was paired with an upgraded cylinder head to increase the durability of the 2004.5-2007 common-rail 5.9L Cummins engine. Inconel exhaust valves and high-cobalt exhaust valve seats were included in the cylinder head to improve heat and wear resistance. The forged-steel connecting rods continued to prove their durability, hence why they had been utilized since the first generation Cummins. An oil cooling gallery was added to protect the upgraded pistons from increased in-cylinder heat. The cast-aluminum pistons feature a redesigned fuel bowl area to match the new spray angle of the fuel injectors. The new injectors feature 5 hole nozzles with a 124-degree spray angle and produce 3 injection events per stroke. The third injection event was called post-injection, which was designed to raise in-cylinder heat after the main injection event. To further increase performance the turbocharger was upgraded to the Holset HE351CW turbocharger. This fixed-geometry turbo features an electronic wastegate to better manage the boost-to-drive pressure ratio.
The transmission options for the 2004.5-2007 common-rail 24 valve 5.9L Cummins were either the 48RE 4-speed automatic transmission or the G56 6-speed manual transmission. In 2004 the high-output Cummins was paired with a manual transmission and was rated at 325 hp and 600 lb-ft of torque, while the standard output option with an automatic transmission was rated at 305 hp and 555 lb-ft of torque. From 2005-2007 all Cummins-powered trucks paired with either an automatic or manual transmission were rated at 325 hp and 610 lb-ft of torque. As the battle for highest horsepower and torque continued, the common-rail 5.9L 24 valve Cummins engine was discontinued after the first half of the 2007 production year and replaced by the 6.7L Cummins. The 5.9L Cummins maintains its reputation for reliability and many trucks powered by this engine are still on the road today. XDP continues to support the common-rail 5.9L 24 valve Cummins with a large selection of parts from hundreds of the top manufacturers. Whether you need Fuel Filters and Oil Filters for routine maintenance, or if you need Fuel Lift Pumps and Turbo Upgrades for a performance boost, XDP has what you need. XDP is your one-stop-shop for everything you need to get the most out of your 2004.5-2007 Dodge 5.9L 24 valve Cummins.