5.9L Cummins “Heavy Hauler” Ready-Run Engines — Built for Work, Tuned for Longevity

Blueprinted long blocks paired with BD air & fuel systems and heavy-duty hardware. Drop-in reliability for Ram 2500/3500 owners who tow, haul, and need a proven 700 hp-capable foundation—without the guesswork.

Quick Summary: D&J Stage 1 CNC-ported head • ARP 9/16" head studs (175 ft-lb) • D&J tow cam & 7/16" pushrods • BD two-piece ductile iron manifold • BD Screamer turbo (63/76) • Reman CP3 + injectors, Bosch-bench tested • Full line set, gaskets, sensors, Fluidampr, water pump • Ready-Run: pre-lubed, painted, break-in oil & filter included.

Choose Your Fitment

Both versions share the same Heavy Hauler recipe—specs below include year-specific fitment and links.

2006–2007 Ram 2500/3500 • 5.9L Cummins

Ready-Run long block + BD Screamer 63/76 turbo, BD two-piece manifold, full HP fuel system, sensors & ancillaries.

View 2006–2007

2004–2005 Ram 2500/3500 • 5.9L Cummins

Same heavy-duty spec with year-correct hardware and calibration details handled.

View 2004–2005

What Makes a “Heavy Hauler” Different

1) The Long-Block Foundation

  • Comprehensive inspection & machining: Disassembled, crack-checked, blasted/cleaned; CNC bored/line-bored; torque-plate honed; surfaced to spec.
  • Head seal you can trust: Custom ARP 9/16" studs torqued to 175 ft-lb for clamp load that keeps your coolant where it belongs.
  • Airflow & valvetrain: D&J Stage 1 5-axis CNC-ported head with heavy-duty seats, performance valve job; D&J tow cam; HD 7/16" pushrods; machined rocker box & pedestals.
  • Blueprinted & balanced: Bearing clearances measured, ring gaps set, fully balanced rotating assembly.
  • Ready-Run: Pre-lubed, painted black, shipped with break-in oil and filter.

2) Air In, Air Out: BD Screamer + Two-Piece Manifold

  • BD Screamer Turbo (5.9L spec): 63 mm billet compressor + high-flow 76 mm turbine, VSR high-speed balanced; adjustable wastegate preset at ~30 psi for crisp response.
  • BD Two-Piece Manifold: High-silicon ductile iron casting handles heat cycling; improved pulse energy and serviceability under tow duty.
  • SEMA Certs: SC-BDD01-0078 (manifold), SC-BDD01-0152 (turbo).

3) Fuel System You Don’t Have to Second-Guess

  • Bosch-trained reman CP3 + injectors: New metering unit on CP3; injectors and pump validated on a Bosch 815 bench across multiple operating points.
  • Complete line set & gaskets: BD OEM-fit lines for clean install and leak-free performance.

4) The Small Things That Prevent Big Problems

  • Fluidampr harmonic balancer to control torsional vibration.
  • New water pump & thermostat, new oil pressure & coolant temp sensors.
  • Turbo oil feed & drain, new Bosch fuel rail w/ pressure sensor & relief valve.
  • High-pressure injector feed tubes, dipstick & tube.

Who It’s For

  • Tow/haul fleets & RVers who want factory-smooth drivability with real thermal headroom.
  • Work trucks that see long grades, high ambient temps, and idling—where clamp load, oil control, and cooling matter most.
  • OEM-plus builds targeting up to ~700 hp with the right supporting mods and calibration.

Install Time

~ 14 hours 30 minutes (shop dependent).

Warranty

24-Months / 100,000 Miles (Parts). See product page for details.

Emissions

This replacement product is legal for sale and use in all 50 states by nature of its design (EMS:4).

Year-Specific Notes

  • 2004–2005 vs. 2006–2007: Hardware and calibrations are handled within each Ready-Run to match your model year and simplify install. Use the correct link above for your truck.
Recommended Pairings
• BD 5.9L Injectors (Stock, StockPlus, Premium) — OE-quality replacements validated on Bosch 815
• BD Exhaust Manifold & Turbo hardware — maintain clamp load and thermal durability
• BD Transmission packages (47/48RE) — for trucks pushing heavy tow duty or added power

Shop 5.9L Heavy Hauler — 2006–2007 Shop 5.9L Heavy Hauler — 2004–2005

5.9L Cummins Heavy Hauler Ready-Run Engine Towing & Hauling BD Screamer Turbo ARP 9/16 Studs

Always verify fitment, torque procedures, and break-in steps on the product page. Keep emissions equipment intact and compliant. Professional installation recommended.