1998 - 2007 5.9L Cummins ISB Service Information

5.9L 24v Cummins Maintenance schedule, Fluid Specs/Capacities, & Service Part Numbers

"Severe" driving conditions includes any or any combination of the following:

• Excessive idling
• Frequent short trips or start-shutdown cycles in which the engine does not reach full operating temperature
• Driving in dusty environments
• Driving off-road or in conditions that require the use of 4 wheel drive
• Frequent towing or hauling

5.9L Cummins ISB (24v) Maintenance Schedule

Note - All service intervals are the maximum recommended period before the service procedure should be performed. Always adhere to the OEM recommendations regarding alternative maintenance schedules for vehicles falling under the "severe duty" or "heavy duty" conditions. If unsure which service category your vehicle falls under, follow the "severe" maintenance schedule.

Service Procedure

Intervals

Replace engine oil & oil filter

1998.5 - 2002

7,500 miles/6 months under normal driving conditions
3,750 miles under severe driving conditions

2003 - 2007

15,000 miles/12 months under normal driving conditions
7,500 miles/6 months under severe driving conditions

Replace fuel filter

1998.5 - 2002

15,000 miles under normal driving conditions
7,500 miles under severe driving conditions

2003 - 2007

15,000 miles/12 months

Flush engine cooling system

1998.5 - 2002

30,000 miles/24 months

2003 - 2007

100,000 miles/5 years

Inspect water pump

15,000 miles (inspect weep hole for blockage)

Replace automatic transmission fluid & filter

1998.5 - 2002 (47RE)

30,000 miles

2003 - 2007 (48RE)

100,000 miles

Adjust automatic transmission bands

1998.5 - 2002 (47RE)

30,000 miles

2003 - 2007 (48RE)

100,000 miles

Replace manual transmission fluid

60,000 miles (undefined by OE, 3rd party recommendation)

Replace transfer case fluid

120,000 miles under normal driving conditions
60,000 miles under severe driving conditions

Replace front differential fluid (4x4)

1998.5 - 2002
Dana axles

30,000 miles under severe driving conditions
Interval undefined by OE under normal driving conditions

2003 - 2007
AAM axles

15,000 miles under severe driving conditions
Interval undefined by OE under normal driving conditions

Replace rear differential fluid

1998.5 - 2002
Dana axles

30,000 miles under severe driving conditions
Interval undefined by OE under normal driving conditions

2003 - 2007
AAM axles

15,000 miles under severe driving conditions
Interval undefined by OE under normal driving conditions

Check/adjust valve lash

150,000 miles

5.9L Cummins ISB Service Part Numbers

Engine air filter

1998.5 - 2002

Fleetguard AF25541

2003 - 2007

Fleetguard AF26106, WIX 49946

Engine oil filter

Fleetguard LF16035

Engine oil drain plug

1998.5 - 2002

Mopar 4778578

2003 - 2007

Mopar 05080631AB

Engine oil fill cap

Cummins 3973511

Fuel filter

1998.5 - 1999

Fleetguard FS19598

2000 - 2002

Fleetguard FS19855

2003 - 2007

Fleetguard FS19856

Fuel tank cap

1998.5 - 1999

Stant 10819D

2000 - 2007

Stant 10838D

Serpentine belt

1998.5 - 2002

Gates K080810 (single alt w/ AC)

2003 - 2007

Gates K081264 (single alt w/ AC)

Belt tensioner assembly

1998.5 - 2002

Gates 38175

2003 - 2007

Gates 38285, Cummins 3947574

Lift pump (fuel pump)

1998.5 - 2002

Carter P74213 (OEM, electric inline pump)

2003 - 2004.5

Carter P76110 (OEM, electric inline pump)

2004.5 - 2007

Carter P76148M (OEM, in-tank, 34 gallon short bed)

2004.5 - 2007

Carter P76611M (OEM, in-tank, 35 gallon long bed)

Thermostat

Stant 14289

Thermostat housing gasket

Mopar 53021051AB

Radiator cap

Stant 10230

Upper radiator hose

1998.5 - 2002

Gates 22645

2003 - 2007

Gates 22892

Lower radiator hose

1998.5 - 2002

Gates 22082

2003 - 2007

Gates 22893

Water pump

Gates 43526

Automatic transmission filter

Mopar 52118789 (47RE/48RE)

Transmission pan gasket

Mahle W39003TC (47RE/48RE)

Differential cover gasket

Dana 60/70

Victor Reinz P18562

9.25" AAM, front

Fel-Pro RDS55474

10.5" AAM, rear

Fel-Pro RDS55472

11.5" AAM , rear

Fel-Pro RDS55473

1998.5 - 2007 Ram 2500/3500, 5.9L Cummins ISB Fluid Specs & Capacities

Note - All units of measure used herein refer to U.S. measurements, NOT Imperial. All fluid capacities are nominal and to be used for the purpose of purchasing an adequate amount prior to service. Always bring fluid level to proper indicating marker on dipstick, bottom of fill plug hole, etc. Always recheck fluid level after driving vehicle. Some fluid capacities may vary for chassis cab trucks; the following specifications are based on 2500/3500 pickup models.

Engine oil

1998.5 - 2002

15W-40, ambient temperature > 10° F

12.0 qts w/ filter

1998.5 - 2002

10W-30, ambient temperature 0 to 30° F
(30 to -10° F w/ block heater)

1998.5 - 2002

5W-30, ambient temperature 0 to -10° F (w/ block heater)

2003 - 2007

15W-40, ambient temperature > 0 ° F

2003 - 2007

5W-40 full synthetic, all ambient temperatures

Engine coolant

50/50 mixture Mopar 5 year/100,000 mile anti-freeze (MOPAR 68048953AB) and distilled water

~ 6 gallons (1998.5 - 2002)
~ 7 gallons (2003 - 2007)

Automatic transmission fluid

MOPAR ATF+4 automatic transmission fluid (48RE, MOPAR 5013457AA)

~ 4.0 qts service refill
14.5 - 16.5 qts total capacity

Manual transmission fluid

NV4500 HD
(5 spd)

75W-90 Castrol Syntorq (75W-85 MOPAR 4874459)

4.0 qts (8 pts)

NV5600
(6 spd)

MOPAR manual transmission fluid (MOPAR 4874464)

4.75 qts (9 pts)

Transfer case fluid

NV231HD

MOPAR ATF+4 automatic transmission fluid
(MOPAR 5013457AA)

1.25 qts (2.5 pts)

NV241

2.3 qts (4.6 pts)

NV241HD

3.25 qts (6.5 pts)

Front differential fluid

Dana 60

SAE 75W-140 synthetic gear oil

3.15 qts (6.3 pts)

9.25" AAM

SAE 75W-90 GL-5 synthetic gear oil

2.45 qts (4.9 pts)

Rear differential fluid

Dana 70 2WD

SAE 75W-140 synthetic gear oil

3.5 qts (7.0 pts)

Dana 70 4WD

3.9 qts (7.8 pts)

Dana 80 2WD

3.2 qts (6.4 pts)

Dana 80 4WD

4.8 qts (9.6 pts)

10.5" AAM

SAE 75W-90 or 75W-140 (preferred for towing) GL-5 synthetic gear oil

2.65 qts (5.3 pts)

11.5" AAM

SAE 75W-90 or 75W-140 (preferred for towing) GL-5 synthetic gear oil

3.8 qts (7.6 pts)