2004.5 - 2007 Dodge Ram Performance Parts | 3. generation of Cummins 5.9L (2024)

For many, the 2004.5-2007 Rams with the last iteration of a 5.9L Cummins nestled in the engine bay of a heavy-duty Dodge prior to the 6.7 Cummins conversion are truly a relic. That's why many of us choose to keep them on the road as the miles continue to pile up in silent protest against the latest vehicle technology.

If you are the proud owner of one of these "classics", you are in luck, as we stock a significant collection of replacement and upgraded parts to suit every taste. But before we get started, we must first explain to those with a "2004" how to identify whether you have a "2004" or a "2004.5", as it is very important to understand because between this mid-model year is different injectors, turbo, exhaust systems, valve bodies and much more. One of the easiest methods is from the factory: a 2004.5 has a 4-inch full diameter exhaust and a catalytic converter at the bottom of the downpipe. The early 2004 models have a 3.5" downpipe without a cat and then adapt to a 4" exhaust. Another way to check this is to find the red or silver plate on the driver's side of your engine. On a 2004.5 the plate says 600 torque or 325 hp. The 2004 one says 305 hp. If you're still unsure, call your local Dodge dealer with the last 8 digits of your VIN and they can get it for you. clarify for you.

In terms of performance parts, you're in luck. The diesel performance industry fully supports these trucks for everything from common repair parts like two-piece exhaust manifolds to solve the common manifold crack problem, to composite turbos to ease your power needs. Because these are trucks within this 2.5 model year range, there are a few additional things worth mentioning. First, the injectors originally supplied in these trucks were often referred to as the "505" injectors due to their original Bosch part number, 0 986 435 505, updated from their original design. Often while still under the factory warranty, these trucks were notorious for eating injectors which would cause hard starting, poor fuel economy, loss of power, white smoke, and so on. To fix this, Bosch made several updates to the injectors to fix the problem, which they did. Additionally, when the 6.7 Cummins came out, the connecting lines that connect each injector line to a corresponding injector were updated. The original 5.9L iterations would wear internally, but the 6.7L versions were built of a harder metal that could better withstand the high pressure they were exposed to. That's why many choose to use the 6.7 versions, including Ram dealers themselves.

Ram and Cummins made a big change, starting with the 2006 model, with the adoption of a CAN Bus-compatible ECM, simply put, a much smarter version of the previous ECM. Because of this upgrade, the available chips and programmers will typically only fit a 2004.5-2005 model versus a 2006-2007 model. For example, Edge Juice with Attitude has one part number for the early models and another for the later models. Furthermore, brands like EFILive only support the later model 5.9s.

For those of us looking to improve the performance of your Cummins, the sky really is the limit. For most people, a step-by-step approach works best. For example, you start with a cold air intake and an exhaust upgrade. Then it's time to add a chip or programmer. After that, it's a good idea to replace the weak factory lift pump with a larger volume unit. Then replace the turbo and while you're at it, you might as well upgrade the exhaust manifold. Okay, the old truck runs pretty good now, but the injectors are a little tired, might as well go with a set of 60 or 90 hp injectors. At this point it may be time to upgrade the CP3 injection pump so it can better handle the larger cylinder injectors. And it just goes from there, and as long as it's done thoughtfully, the results at every stage will make for a great driving experience.

One thing a 3rd generation Ram isn't known for is impeccable ride and tight steering. But that's no problem, because there are countless manufacturers that specialize in making your steering smooth and up to any task. One of our most popular upgrades for these trucks is replacing the waste plant steering gearbox with a Red-Head replacement. No, it's not just your local parts replacement that only takes two years, trust us on this. Or maybe you're tired of how fast your truck drives, but you still need one that can handle your heavy trailers. No problem, we have a choice of brands such as Carli Suspension, specialized in this specific department. How about taking your truck down a rough back road or into the mountains? From mild to wild, we can help. And just like the performance example above, we can help you build your suspension in stages.

In short, at Diesel Power Products we have everything you need for your 5.9L, including AirDog and FASS fuel systems, Diamond Eye and MBRP exhaust systems, ISSPRO EV2 and Autometer Factory Match gauges, BD-Power Turbo upgrades, Dynomite diesel injectors, Mag-Hytec Transmission and differential covers, Smarty programmers, Valair and South Bend clutches, Carli suspension, Snow Performance water/methanol injection systems and much, MUCH more.

The products in this section are designed for use on model year 2004.5, 2005, 2006 and 2007 Dodge trucks equipped with the 5.9 liter Cummins unless otherwise noted. But as always, if you have any questions about fit, performance, results, please don't hesitate to call or email us, we'll be happy to help.

Disclaimer:
Diesel Power Products is not affiliated with Cummins or any of its subsidiaries or related companies. Unless a product is specifically identified as a genuine Cummins product that has not been reconditioned, modified or refurbished, Cummins makes no representations or warranties about the product and has not authorized, tested or approved the parts for use in genuine Cummins branded products .

Every day we receive many telephone calls and e-mails with various questions about products, vehicles and installations. Some are completely strange and can even catch us off guard at times, but many others are quite routine, so we thought we'd post some of the most popular questions that can hopefully be a good resource for you.

Question: How do you know if your Cummins is a 2004.5 or a 2004?
A: There are two ways. First, you can check the driver's side valve cover based on the estimated horsepower. If the truck is a 2004, 305 is listed, while the 2004.5 models are rated at 325 hp. Second, the early 2004 (non-California) models did not have a factory catalytic converter, while the 2004.5 models do. If your exhaust is still original, you can easily check this.

Question: What is the difference between the 2007 and 2007.5 Cummins?
A: In 2007.5, Ram introduced a 6.7 liter emissions controlled engine, up from the 5.9 liter they had in 2007. The 6.7 liter has more power and was equipped with a factory EGR (Exhaust Gas Recirculation) system and DPF (Diesel Particulate Filter). ) in the exhaust. Both were done in response to tightened EPA regulations that went into effect on January 1, 2007.

Question: Do I need the Extreme Duty Red-Head gearbox or the regular unit?
A: Extreme Duty is built for those who use unusually large tires, such as a very wide diameter 35 inch or 37 inch or larger. This model would also be a good idea for vehicles that are regularly used off-road.

Q. Why does my transmission sound like it is rattling after I install a new clutch?
A. The noise you hear is called gear noise. It is clearly visible in all transmissions, which is why the factory initially installs dual-mass flywheel clutches on the G56 model starting in 2005, because they want to reduce that noise. The G56 is particularly bad because it has a large aluminum housing that doubles as a megaphone. It is a completely normal condition, but something can be done about it. We generally recommend adding the fluid up to the filler plug in the transmission, then pulling the shift tower and adding an extra quart. This will significantly reduce the rolling noise of the gears.

Question: I'm looking at an exhaust kit on your website, but it doesn't say which cab and bed configuration it fits. Does this fit my application?
A: In most cases, all exhaust kits on our website will fit all cab and bed lengths unless specifically stated to fit a particular configuration. In addition, most kits are not suitable for cab and chassis applications unless otherwise stated.

Question: I'm looking at this 5" (or other) exhaust kit, but my truck only has a 4" exhaust now. Is an adapter/reducer included with this 5" exhaust?
A: Yes, the exhaust systems we sell adapt to the application at the specified starting point (turbo rear, cat back, DPF rear, etc.) for a hassle-free installation.

Q: What are EGTs?
A: EGT stands for Exhaust Gas Temperature, the temperature of the exhaust gases leaving your engine. This measurement is usually taken before the turbo to ensure that the components do not overheat. For most applications we recommend not exceeding a temperature of 1300 degrees.

Q: Do you offer smoke and lope tunes with any of your preloaded EFILive AutoCal options?
Answer: No, we don't. In short, both smoke and lope tunes produce these results, to the detriment of the overall reliability of your engine. The tuning companies we have worked with are top notch and are most interested in creating more power, fuel economy and overall drivability. We at Diesel Power Products invest a significant amount of time and effort to ensure that the products we recommend are in the best overall interest of our customers and their trucks, and unfortunately these types of tunes do not align with the overall goal.

If you have a question about your Cummins, please feel free to call us at 888-99-DIESEL. We are happy to help you.