Hello Was just wondering if anyone could help point out some common known problems with the Cummins 5.9L. Currently I own a 6.0 Powerstroke and regret buying it as it is costing me a fortune in repair costs and it doesn't seem to be coming to an end any time soon. In saying that I am interested in perhaps buying a Dodge with the Cummins engine instead. Any direction on what to expect with these engines, reliability, cost to repair, common problems as opposed to the 6.0 PS would be appreciated. Thanks!

Depending on which year Dodge you get, there can be various (and changing) issues.

Here is a good place to start:

http://www.genosgarage.com/GenosGara...arageWWWMT.pdf

Note that EVERY vehicle out there, diesel, gas, car, truck, import, American, or any other category you want to think of, WILL have a series of issues that have cropped up in that platform over time. So, in essence, you trade one set of problems for another set of problems, which may or may not be easier to deal with, less or more expensive, or more in line with your intended use and/or skill sets and wallet depth.

After 30+ years in the business, I've come to realize that certain makes and models have recurring problems, for instance, you can COUNT on replacing the steering rack on a front-wheel drive model Ford Taurus at some point in its life. You can COUNT on replacing the transmission in a Dodge mini-van at around 70K miles. You can COUNT on the killer dowel pin being a problem on a 12V Cummins, and you can COUNT on having other problems with other platforms.

You can also COUNT on the fact that fans of a particular model will overlook their own problems and point out those in other lines... That being said, in my own case (I'm NOT a big fan of Dodge products) I looked at the Cummins diesel in the Dodge trucks and decided that the ENGINE is worth the other problems that I might find in the Dodge truck platform. For me, best of all worlds would be a Ford truck with a Cummins engine. That may yet happen when my Dodge turns into a rusty red spot with a still-great Cummins sitting there exposed to the elements. It is hard to top an engine that can easily, reliably, and inexpensively be tuned to produce close to 400 hp, 800 ft. lbs. of torque, and that pulls down over 20 mpg while doing so.

Seems the injectors are a problem on the common rails expect about 60k on a set that's average some do better! Some worse!! I put a brand new injector in 6 months ago and that same injector failed and fryed my engine! Otherwise pretty awesome engine!

The lift pumps seem to be a common problem, but nothing an Air Dog or Fass can't address, while at the same time paving the way for future upgrades like bigger injectors, etc.

I got a problem with mine - Every time I step on the gas the back tires break loose and you couldn't get the grin off my face with a baseball bat! I am also sick of looking in my rear view mirror wondering where all the dura's , strokes, and stangs fell back to.

X-2 on the lift pump it is a mandatory replacement. And somehow, I managed to toast a clutch before I chipped the thing out even... Those are the only major problems I have had with the engine/drivetrain. Most of the problems I have encountered over the years have been small annoying ones like the dash cracking in 10 places, the windows quitting due to both switches going at once (at -20 by the way and one window down a little....) the seats are like sitting on bricks, and the heat is a little sub standard for the north country. Otherwise, I look forward to putting a million miles on this monster, and I have 185K right now, basically problem free. Did I mention the 20+ mph @300 HP?

The single best mod one can make to a CR engine is upgrade the fuel delivery and filtration. Once you do that, all the major issues become minor.

The only other issue is the cost of keeping a trans\clutch behind it. Solid options are available at a reasonable price.

thank you for your responses gentlemen. i might have to seriously consider the cummins.

Either that or look for a cummins for your Ford, they plenty of sites telling you how to do it right the first time.

Also on a more serious note - the lift pumps are the weak link. Look under the hood of a dura or stroke and you can see the Cummins is by far the easiest to work on. It is literally the "small block chevy" as far as aftermarket is concerned and can be made really powerful and efficient. The second weak link becomes the transmission when you get addicted to power enhancement. Even most "boxes" have enough extra juice to overpower the transmissions - especially when doing things with your vehicle that your Mom wouldn't told you not to. But all things do have remedies that will meet all your goals. Also remember at the same horsepower levels the Cummins always has more torque than the others. Torque is what you feel - horsepower is a number.

i second the lift pump issue, its coverd under your engines warrenty tho, for 100000 miles, also i hear of injector issues, i think if i could do it all again, i would find a 98 12 valve with a 5speed. imho i would rather have that truck than my 04, the seats are very uncomfertable depending on the model mine is basline the seats are like sitting on a brick...the power is nice but i miss the simplicity and cheapness of the older engine, but tuning on the fly is fun. i would rather a cummins powered dodge over any ford or cheby truck. i drive a 2007 6.0 f550 for work every day, it takes a beating but has no ***** comparid to my 04 cummins powerd dodge and also is less atractive to the eye. buy a dodge with the cummins get a 6speed if you want to save money or if you keep is stock get an auto, they are great trucks. buy and enjoy

got 137k on mine, had to change an idler pulley on it, dual mass flywheel went bad replaced it with a solid one from Southbend. Stay on top of the fuel filter changes and anytime mine starts idling a little rough I dump some Seafoam in it and that usually solves it. CR 5.9s don't like dirty fuel at all. Oh yeah I've also had to replace all the u-joints(steering knuckles,front drive, and rear) and 1 front wheel bearing hub assembly.

ahhhahaha thats the $h!t

I know I'm resurrecting an old thread, but for future readers looking for answers to the same question here is my experience;

I have a 2004.5 3500 4x4 Quadcab. Liftpump went out at 20k, dealer replaced it under warranty. I had the bullydog chip for awhile and burned out my trans at 109k miles. Had a tensioner pulley and water pump go out after that but don't remember the mileage. Batteries quit somewhere around 170k miles (got 5yrs out of them). Front driveshaft wore out somewhere around there, the bearing in the double knuckle wore out if I remember correctly and created a vibration that was rather annoying. Around 208k miles I had some trans shifting issues that I fixed with a couple hundred dollars in parts. (I had neglected the regular filter changes for 100k miles... I know... WTF was I thinking?) Around that same time my transfer case started making some nasty popping noises when I put it in 4wd. At about 228k miles I replaced the entire steering tie rod/pitman arm/ball joints and the vacuum pump for the cruise control. Now at 234k miles I'm having the starting problem that I believe is injectors. Needs ether for the first start of the day (I know, I've done the search and everyone on here says "don't use ether!!!") and after that it will start fine. Let it sit overnight and it needs another shot.

Other than that it's been a great truck. I've been staying on top of the maintenance as I want to get a million miles out of this truck.

I agree, with 125xxx I'm doing ball joints and front drive shaft U joints and replacing two tie rod ends. to the tune of 700.00,
As far as cummins there rock solid, just clean up the fuel. mopar on the other hand could have done better... I.E. window switch issues and those damn front wheel bearing's. good thing the after market is there...