Failure of 5.9L Cummins Turbocharger

by MOU YONG HONG on December 01, 2021
In 1998, Dodge phased out the much-lauded 12 valves 5.9L Cummins turbo diesel in their medium-duty pickup trucks with an improved 24 valve version that featured common rail injection and increased power output. Further refinements of the 24 valve 5.9L Cummins further increased performance with a high-output version which offered over 100 horsepower more by the top of the engine's run in 2007. For nearly a decade, the 24 valve 5.9L Cummins remained the facility plant of choice for a generation of diesel-powered Dodge trucks and it quickly secured its own legacy together of the simplest engines offered by Dodge.

While usually thought to be one among the last true bullet-proof diesel engines, the 24 valve 5.9L Cummins engine does have a couple of common problems that will cause serious issues over the future. Chief among these problem areas is that the Holset turbo which may fail, especially on higher-mileage vehicles. This usually causes a scarcity of boost pressure within the intake, leaving you down on power, or within the worst case, catastrophic engine damage if left undiagnosed.

The most common point of failure for the factory 5.9L Cummins turbo is that the oil seals. Often, worn seals within the center hub rotating assembly will allow the grease into the intake and also the exhaust. Engine oil within the intake is often particularly bad during a diesel because it can't only clog your intercooler, but it also can cause an unexpected increase in engine RPM beyond your throttle input. The oil within the exhaust on the opposite hand can damage your oxygen sensors and cause excessive smoke with a bluish tint from the tailpipe. While it's fairly easy to note a smoky exhaust and an oily tailpipe, oil within the intake can only be observed by disassembling the post-turbo charge pipes and induction system. Some oil residue is common within the intake system, but if you discover pools of oil you are looking at a severely worn turbo.

Another sort of turbo failure occurs when the bearings within the middle hub rotating assembly begin to wear. this will be caused by age and high-mileage, or from a scarcity of lubrication due to a clogged oil feed line or failed oil seals as discussed above. Because a typical turbocharger can spin much faster than your engine, up to 200,000 RPM, excessively worn bearings can cause the compressor fan to contact the edges of the compressor housing. this may usually cause some chatter from under the hood and in extreme cases cause metal shavings and pieces of the compressor blade to enter the combustion chamber where it can cause serious damage to the engine's internals.

The earliest wake-up call of bearing failure may be a loud whine or whistle during acceleration that increases or decreases with RPM and cargo. you'll also visually inspect the turbo for excessive bearing play by removing the intake tube that feeds the turbo then moving the compressor fan together with your fingers. a little amount of fore and aft play is that the compressor shaft normal, but any play to the side or any amount that causes the fan to hit the edges of the housing indicates worn bearings. The compressor fan should also turn freely by hand without resistance. If you encounter either situation, you will need to exchange the turbocharger unit.

When it is time to exchange your original turbo, confirm you order the right one for your specific truck. While the 5.9L was available in these trucks for quite 15 years, there are a few slight variations listed below:

24v 5.9L Cummins Holset Turbo

Genuine New OEM Holset Turbochargers for Dodge 24v 5.9L Cummins Diesels

HX35W Turbocharger 3539697 3804877 3539700 3539699

3536971 HX35-L8264AC Turbocharger

4035373 Turbocharger stocks Genuine New Holset Turbochargers for the 5.9L Cummins diesel which will restore in your Dodge Ram truck the performance lost from a worn or failed turbocharger. These turbos are new a bit like the other Holset turbo that you simply can buy from your dealer, but without the dealer prices. We also stock complete Holset Turbocharger installation kits for the 5.9L Cummins diesel that include every gasket you would like to attach your new turbo right. We recommend purchasing the 5.9L Cummins turbo installation kit with oil feed line so you'll make certain that your new turbo is lubricated without restriction in which your oil system isn't contaminated by metal shaving from you old worn-out unit. If you've got any questions on which turbocharger you would like for your 5.9L Cummins diesel, call one among our certified parts experts at +8619183973182, drop us an email, or use or easy on-site live chat feature found on every page of our site.


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