2003–2007 RAM 2500/3500 · 5.9L COMMON-RAIL CUMMINS
3rd-gen 5.9 Cummins performance upgrades in Tucson: more power that lasts.
The common-rail 5.9 makes big, reliable power when it’s built in the right order. Here are the Stage 1 to Stage 3 builds we install on 2003–2007 Rams, plus the lift pumps, transmission, exhaust, suspension and air suspension upgrades that go with them, all done at your location.
- 305–325 hp555–610 lb-ft stock
- Bosch CP3common rail
- 48RE · NV5600 · G56transmissions
- We come to youTucson & nearby
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KNOW YOUR TRUCK
Early or late 5.9? It changes the fix.
Several parts changed mid-run. Tell us your year (or read the tag on the driver’s side of the engine block) and we’ll bring the right parts the first time.
Early common rail
- 305 hp / 555 lb-ft (High Output)
- Holset HE341CW turbo
- Engine-mounted lift pump (the failure-prone one)
- Accelerator pedal sensor (APPS) prone to “dead pedal”
- NV5600 six-speed manual or 48RE automatic
“325” update
- 325 hp / 600 lb-ft
- Holset HE351CW turbo
- Catalytic converter added
- Block tag reads 325 hp or 600 lb-ft
Late common rail
- 325 hp / 610 lb-ft
- Lift pump moved into the fuel tank
- G56 six-speed manual replaced the NV5600 during 2005
- 48RE automatic all years
- Replaced by the 6.7 during the 2007 model year
PERFORMANCE UPGRADES
More power that lasts.
The common-rail 5.9 responds very well to upgrades, and its bottom end is stronger than the parts around it. The transmission, head gasket, clutch and fuel supply are what limit it, so we build power in stages and upgrade those parts with it. Gains depend on your truck and its supporting parts.
Daily driver & light towing
- Emissions-compliant tuning: Edge EZ, Evolution CTS3 or the new CTS4, or Banks
- Banks Ram-Air intake + Banks Monster-Ram intake elbow (or S&B, WCFab)
- Cat-back exhaust that keeps the factory catalytic converter on 2004.5–07 trucks (MBRP, Banks)
- Gauges to watch exhaust temp and transmission temp
- 48RE: deep pan and cooler at minimum
Typical result: noticeably stronger pulling and better throttle response.
Call for a quoteRequest a quoteSerious towing
- Everything in Stage 1
- FASS lift pump
- Upgraded injectors (S&S Diesel Motorsport, sized for early or late 5.9)
- ARP head studs
- Built 48RE from Randy’s Transmissions (Stage 2 is rated to 650 hp)
- Heavy-duty clutch on manuals
- Exhaust brake
Typical result: big towing power with temperatures under control.
Call for a quoteRequest a quoteBig power
- Everything in Stage 2
- Drop-in performance turbo (BD Diesel Screamer, Stainless Diesel, Stealth 67)
- CP3 upgrade for more fuel
- Banks Techni-Cooler intercooler (comes with the Monster-Ram and boost tubes; separate kits for 2003–05 and 2006–07)
- Randy’s Stage 3 or Stage 4 48RE and a built driveline
- Front-end and steering upgrades to handle it
Some Stage 3 parts are for off-road or competition use only. We’ll tell you which.
Call for a quoteRequest a quoteUPGRADES BY CATEGORY
Pick a category to see the parts we install.
Tap a tile to see what it fixes and the parts we install on the 3rd-gen 5.9. Every truck is different, so call or request a quote for yours.
Emissions-compliant tuners
A tuner is the first power upgrade on a 3rd-gen, but the 48RE is the weak link. At minimum we add a deep pan, cooler and transmission temperature gauge with any tuner.
Parts we install
- Edge EZSimplePlug-and-play module with separate versions for 2003–04 and 2004.5–07 trucks.
- Edge Evolution CTS3Tuner and color-screen monitor in one.
- Edge Evolution CTS4NewEdge’s newest tuner and monitor with a bigger, sharper screen. We confirm availability for your truck.
- Banks tuning + iDashWe match the Banks tuner to what Banks currently makes for the 5.9, paired with an iDash gauge.
Banks Ram-Air, Monster-Ram & intercoolers
These are the Banks parts we like on the 3rd-gen 5.9, plus intercooler options for trucks that tow hard.
Banks Ram-Air intake
Part #42145 (oiled filter) · #42145-D (dry filter)
Why we install it: The factory airbox on the 3rd-gen 5.9 is restrictive and pulls warm air from the engine bay. More cool air lets the engine burn its fuel cleaner, which means less black smoke, lower exhaust temps when you tow up grades like Mt. Lemmon or I-10 to Phoenix, and better throttle response. Banks says it lowers exhaust temps and soot. It bolts on in about an hour, it’s 50-state emissions compliant, and it’s the first step that makes every other upgrade work better.
- Direct bolt-on for 2003–2007 5.9 Cummins, no cutting
- Banks rates it up to +28 hp and +52 lb-ft, with 62% less restriction than stock
- Enclosed housing keeps out hot engine-bay air; giant filter with an exclusive bellows that moves with the engine
- Oiled (red) or dry (black) filter. For dusty conditions Banks recommends the oiled filter, which holds dust better
- Optional pre-filter for an extra layer on dirt roads and in monsoon season
- 50-state emissions compliant · 5-year Banks limited warranty
Banks Monster-Ram intake elbow
Part #42765 (elbow) · #42766 (with boost tube)
- Larger, less restrictive casting that replaces the factory intake elbow after the intercooler
- Banks rates it at +1.23 psi boost over stock without raising turbine drive pressure
- Quicker throttle response and more torque, especially when towing
- Up to six 1/8″ NPT ports for pressure, temp or flow sensors
- CNC port-matched to the stock grid heater, so cold starts stay the same
- #42765 reuses the factory boost tube; #42766 adds a 3.5″ mandrel-bent tube · stock intercooler only · 50-state compliant
Grid heater bolt check: On the newer 6.7 Cummins, a grid heater bolt can work loose, drop into the intake and destroy a cylinder. Banks says it hasn’t seen that failure on the 5.9. The 5.9 heater still sits right under this elbow, so while it’s open we check its studs, nuts and connections and replace anything worn or burnt, because it’s cheap insurance.
Pairs best with the Ram-Air intake and a good intercooler. We pressure test for boost leaks when we install it.
Call for priceRequest a quoteParts we install
- Banks Techni-Cooler intercoolerTowingLarger intercooler with the Monster-Ram elbow and 3.5″ boost tubes in the box.
- Mishimoto intercooler kitBar-and-plate intercooler with aluminum pipes and silicone boots.
Drop-in performance turbos
A drop-in turbo makes sense once the truck has fuel and transmission upgrades. Pick the turbo to match your fuel and tuning, and we’ll help you size it.
Parts we install
- BD Diesel Screamer HE351CWOur pickNew (not rebuilt) drop-in with a 63mm billet compressor wheel.
- Stainless Diesel 5-blade HE351CWDrop-in with billet compressor wheels in several sizes.
- Calibrated Power / WCFab Stealth 67Drop-in upgrade for 2003–07 5.9 trucks.
FASS lift pump, filtration & injectors
The factory fuel filter is rated around 7 microns, coarser than the 2–4 microns these injectors want. Better filtration and a strong lift pump are the best reliability upgrades on this truck.
Parts we install
- FASS lift pumpOur pickWater separation and extra filtration in one system.
- S&S Diesel Motorsport injectorsNew or remanufactured performance injectors.
- CP3 upgradeMore fuel volume for high-power builds.
48RE & manual upgrades
The 48RE is the weakest link behind the Cummins. Start with cooling, then build or replace it to match your power and towing.
Parts we install
- aFe Power deep panStart hereCast aluminum pan with cooling fins.
- Fleece transmission coolerReplaces the factory cooler.
- Randy’s Transmissions built 48RETowing & powerHand-built in stages to match your power.
- Jasper remanufactured 48REStock trucksRemanufactured to factory specs.
- Manual transmissionsHeavy-duty clutch and single-mass flywheel, plus the NV5600 5th-gear nut fix.
Exhaust, manifold & exhaust brake
The cracked factory manifold is one of the most common 3rd-gen problems. Fix it once, then free up the rest of the exhaust.
Parts we install
- BD Diesel Pulse exhaust manifoldOur pick for towingTwo-piece, fully divided pulse manifold in high-silicon ductile iron.
- aFe BladeRunner exhaust manifoldOne-piece manifold in stainless or ductile iron.
- MBRP or Banks cat-back exhaustBolt-on cat-back system.
- Pacbrake exhaust brakeTowingAir-actuated exhaust brake.
Radiator, intercooler & trans cooler
Heat kills these trucks in Southern Arizona. We usually refresh the fan clutch, water pump, hoses and coolant along with any of these.
Parts we install
- XDP X-Tra Cool radiatorDirect-fit replacement radiator.
- Mishimoto intercooler kitIntercooler with pipes and boots.
- Fleece transmission coolerReplacement transmission cooler.
Shocks & front end
The heavy Cummins wears out the front end. We rebuild it with parts that last, and we don’t do wheel or tire work.
Parts we install
- Bilstein 5100 shocksFirmer, controlled ride loaded or empty.
- Front-end packageDeath wobbleTrack bar, tie rods, ball joints and steering box.
- Steering stabilizerHelps keep the front end calm on rough roads.
Pacbrake air springs
Rear air springs carry the load so the truck sits level with a trailer or a full bed.
Parts we install
- Pacbrake Alpha HD air springsOur pickRear air springs for 2003–2013 Ram 2500 and 2003+ Ram 3500.
- Pacbrake BRAVO wireless air controlsOptional onboard compressor and controls.
Bypass oil, gauges & bolt-ons
These are easy add-ons we can usually do during another service.
Parts we install
- Insane Diesel bypass oil filterKits for 1998.5–2007 5.9 Cummins, in under-the-hood and frame-mount versions.
- GaugesBoost, exhaust temp, transmission temp and fuel pressure on an Edge or Banks monitor.
- ARP head studsRecommended before adding real power, to keep the head gasket sealed.
- XDP heavy-duty alternator cableReplaces the old, corroded factory cable.
We only install street parts that are emissions-compliant, and we don’t remove or disable emissions equipment. Power gains vary by truck, parts and condition.
FIX IT FIRST
Known weak points come first.
Power exposes weak parts. See every 3rd-gen weak point, the reliability upgrades and the maintenance schedule before you add power.
How mobile service worksTell us your truck and where it is, we diagnose on site, you approve a written estimate, and we fix it where it sits.
See how it works →Name-brand partsWe install proven brands like Banks, BD Diesel, aFe, FASS, Randy’s Transmissions, Jasper and Pacbrake.
See all the brands we install →OWNER QUESTIONS
5.9 performance questions, answered.
Can my 48RE handle a tuner?
Not for long without help. At minimum add a deep pan, cooler and transmission temperature gauge. For towing with added power, plan on a billet converter and valve body or a built 48RE.
Do you install tuners and power parts legally?
We install emissions-compliant parts for street use and do not remove or disable emissions equipment. Some high-power parts are for off-road or competition use only, and we’ll tell you up front.
LET’S TALK ABOUT YOUR TRUCK
Call, text or request a quote.
Tell us your year, mileage, transmission and what you want done. We’ll recommend the right upgrade, quote it and come to you.