5.9L Cummins ISB Maintenance Schedule & Service Info

24v Cummins Maintenance Schedule, Fluid Specs, & Service Guide

Applicable Models:

1998.5 - 2007 Dodge Ram 2500, 3500

Applicable Engines:

5.9L Cummins ISB

Applicable Transmissions:

Dodge 48RE, New Venture NV4500, New Venture NV5600, Mercedes G56

Service Intervals | 1998 - 2007 Dodge Ram, Cummins Turbodiesel

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. Severe driving conditions include, but are not limited to, excessive idling, frequent short trips that keep the engine from reaching normal operating temperature, driving in dusty environments, driving off-road or in conditions that require 4 wheel drive, and frequent towing or hauling. 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

Description

Part Number(s)

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

Oil & Fluid Capacities & Specifications | 1998 - 2007 Dodge Ram, Cummins Turbodiesel

Item

Oil/Fluid Specification

Capacity [1]

Engine oil
1998 - 2002 models

Ambient temp > 10° F

SAE 15W-40 diesel oil
Recommend Amsoil HD 15W-40 synthetic diesel oil

 

12.0 qts w/ filter change

Ambient temp 0° to 30° F
Block heater not required

SAE 10W-30 diesel oil
Recommend Amsoil Max Duty 10W-30 synthetic diesel oil

Ambient temp 30° to -10° F
Block heater required

Ambient temp 0° to -10° F
Block heater required

SAE 5W-30 diesel oil
Recommend Amsoil Max Duty 5W-30 synthetic diesel oil

Engine oil
2003 - 2007 models

Ambient temp > 0 ° F

SAE 15W-40 diesel oil
Recommend Amsoil Max Duty 15W-40 synthetic diesel oil

All ambient temperatures

SAE 5W-40 full synthetic diesel oil
Recommend Amsoil Max Duty 5W-40 synthetic diesel oil

Engine coolant

50/50 mixture Mopar 5 year/100,000 mile anti-freeze (MOPAR 68048953AB) and distilled water
Alternative - Fleetguard CC2820extended life coolant (ELC) [2]

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

Automatic transmission fluid

MOPAR ATF+4 automatic transmission fluid, MOPAR 68218057AA

~ 4.0 qts service refill
14.5 - 16.5 qts total capacity

Manual transmission fluid

NV4500 HD (5 spd)

75W-90 Castrol Syntorq [3], MOPAR 4874459or GM 12346190
Recommend Amsoil synthetic 75W-90 GL-4 manual transmission fluid

4.0 qts (8 pts)

NV5600 (6 spd)

MOPAR manual transmission fluid, MOPAR 4874464
Recommend Amsoil 5W-30 Manual Synchromesh Transmission Fluid

4.75 qts (9 pts)

G56 (6 spd)

MOPAR ATF+4 automatic transmission fluid, MOPAR 68218057AA
Recommend Amsoil Signature Series ATF

4.95 qts (9.9 pts)

Transfer case fluid

NV231HD

MOPAR ATF+4 automatic transmission fluid, MOPAR 68218057AA
Recommend Amsoil Signature Series ATF

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
Recommend Amsoil Severe Gear 75W-140 synthetic gear oil

3.15 qts (6.3 pts)

9.25" AAM

SAE 75W-90 GL-5 synthetic gear oil
Recommend Amsoil Severe Gear 75W-90 synthetic gear oil

2.45 qts (4.9 pts)

Rear differential fluid

Dana 70 2WD

SAE 75W-140 synthetic gear oil
Recommend Amsoil Severe Gear 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 [4] GL-5 synthetic gear oil
Recommend Amsoil Severe Gear 75W-140 synthetic gear oil

2.65 qts (5.3 pts)

11.5" AAM

3.8 qts (7.6 pts)

[1] Listed capacities are nominal; always fill to proper dipstick, fill plug, or fluid level indicator. Oil and fluid levels should be rechecked after driving.
[2] Fleetguard ES COMPLEAT ELC extended life engine coolant is a low silicate formulation that requires no SCA/DCA on initial fill and has an estimated service life of 150,000 miles.
[3] The fluid specification for the NV4500 transmission is highly specific. The (3) listed manual transmission oils are the only known fluids that meet the factory Castrol Syntorq specification. Failure to use a compatible fluid will result in synchronizer failure or other transmission problems. Highly recommend Amsoil synthetic 75W-90 GL-4 manual transmission fluid; it is the most readily available option, OE fluids are becoming increasingly difficult to find and expensive to purchase.
[4] 75W-140 synthetic gear oil recommended by manufacturer when towing.