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The 5.9 Cummins engine or B-Series diesel engine was made between 1984 and 2007. The first generation was the 12V or 12-valve engine. Midway through 1998, the 24V engine was introduced. The official name for this engine was the Cummins ISB 5.9.
This is a fairly legendary Cummins engine that was built before the increase of emissions regulations. Despite its power and durability, it did have some common problems.
The Cummins diesel parts listed here are replacements for various parts that tend to wear out or go bad more quickly than others. You can either preemptively replace these 5.9 Cummins parts before they fail, or you can simply replace them as they wear out.
Throttle Position Sensor (TPS) / Accelerator Pedal Position Sensor (APPS)
The Throttle Position Sensor is a sensor that monitors the air intake of the engine. When a TPS goes bad, the throttle body won’t function correctly. It might stay shut or it won’t close when it should. If it stays shut, your engine won’t start. You might get an error code indicating that the TPS is bad, or you might not.
The Accelerator Pedal Position Sensor is actually a common failure point on the 5.9L 24V Cummins engine and is mostly problematic on the 1998 through 2004 models.
When the sensor fails, it won’t send a signal to the ECM, but sometimes it flashes back on and sends a signal randomly, which can cause the engine to surge. Driving with a failed APPS is dangerous at best and impossible at worst.
Rocker Arm Assembly For 98.5-18 5.9L 6.7L Cummins 24V
The rocker arm is a valvetrain component that transfers pushrod motion to the corresponding intake or exhaust valve. If you have bad Cummins rocker arms, you might experience decreased power and acceleration.
A faulty rocker arm prevents the valves from opening and closing at the correct time. This rocker arm replacement kit from TrackTech includes an intake rocker, an exhaust rocker, two bolts, two rocker shafts, and one rocker cradle for easy replacement.
5 Ply Silicone CAC Intercooler Boot Kit for 94-02 5.9L Cummins 12V 24V
This 5.9 Cummins intercooler boot kit works to replace 24V Cummins parts on engines made between 1998.5 and 2002. It also replaces the same parts on engines made between 1994 and 1998.5.
Rigorous testing in extreme heat and extreme cold has created a CAC boot kit that should be the last one your truck will ever need. It can withstand over 100 PSI of boost, so it will also work for modified trucks.
Transmission Oil Cooler for 2003-2009 Dodge Cummins 5.9L 6.7L 24V
If you’re looking for 24 valve Cummins performance parts to improve your transmission, this transmission oil cooler by TrackTech is available for the 2003 through 2007 5.9L engines as well as the 6.7L through 2009. A transmission cooler works like a heat exchanger.
The hot transmission oil flows through the unit and is cooled down to cycle back into your transmission.
VP44 Injector Lines for 1998.5-2002 Dodge Cummins 5.9L 24V
The fuel system on the 5.9L 24V Cummins engine is somewhat of a weak point. Leaking fuel injectors are a common problem and these usually fail around the 150,000-mile mark. It’s also possible to have leaking injector lines. These VP44 injector lines by TrackTech fit 5.9L 24V Cummins engines made between 1998.5 through 2002.
High Flow Exhaust Manifold for 2003-2007 5.9L Cummins 24V
Another weak point of the 5.9L Cummins 24V engine is the exhaust manifold. Because this engine is an inline six and with 5.9 liters of capacity, the engine block is very long. The 5.9 Cummins exhaust manifold is also quite long. The engine block is made of cast iron, which is a rigid material that expands when the block heats up.
This continued expansion and contraction over a large area causes a lot of stress on the exhaust manifold, which eventually can cause cracking. This 5.9 Cummins exhaust manifold upgrade by Spoologic works for 24V 5.9L engines made between 2003 and 2007.
VP44 Overflow Valve for 1998.5-2002 Dodge Cummins 5.9L 24V
This replacement VP44 overflow valve fits Cummins 5.9L 24V engines made between 1998.5 and 2002. It also includes two new sealing washers. The overflow valve regulates the primary pressure inside the injection pump.
If this pressure doesn’t meet standards, it can affect various systems, including timing and injector function. You might experience symptoms like low power, rough idle, excess smoke, and hard starting. This VP44 overflow valve is also designed in the new style, which is superior to the old factory-installed valves.
Head Studs for 1998.5-2018 Dodge Cummins 5.9L 6.7L 24V
The factory head studs weren’t the best on the Cummins 5.9L 24V engine, but you can replace them with quality Cummins head studs by TrackTech. This kit fits all 5.9L 24 engines made between 1998 and 2007 as well as 6.7L Cummins engines through 2018.
The Cummins head stud kit includes 20 cylinder head studs in the shorter version, six cylinder head studs for the longer exhaust side location, and 26 cylinder head stud nuts and washers. The studs are tested to 240,000 PSI tensile strength, which is the highest in the industry.
HX35W Stock Turbocharger for 1998.5-2002 5.9L Cummins 12V 24V
It’s fairly common to encounter turbocharger problems on the 5.9L Cummins 24V engine. At some point, you may consider simply replacing the turbocharger. This HX35W stock turbo from Spoologic fits engines made between 1998.5 and 2002.
It includes a brass 360 thrust bearing, which is important for one main reason. Brass dissipates heat faster than steel and it can last longer due to not having to hold as much heat. A step gap oil seal provides tighter tolerances to minimize oil leakage from the bearing housing.
Count on ProSource Diesel for a solid selection of Cummins diesel engine parts and replacement diesel truck parts. Whether you’re looking for a kit or a common replacement part, we have you covered with premium diesel parts that meet or exceed OEM standards. That’s why we are where the diesel repair shops shop for parts.
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The post The 5.9 24V Cummins Parts Most Likely to Need Replaced appeared first on Prosource Diesel.
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