5.9 Cummins Power Guide: Stage 1 and 2 Upgrades (1994-2007) | Alligator Performance
The 5.9L Cummins responds to power upgrades better than almost any diesel ever built, but the truck around it was not designed for much more than factory power. This guide lays out two steps for each year range: Stage 1 and Stage 2, each with a towing build and a max power build, all aimed at power that holds up while you tow.
Pick your truck below to see only the parts that fit it. Every product card shows the fitment as it appears on the product page, and the product page has the final word for your exact truck. Parts listed with a CARB Executive Order carry a green badge with the EO number.
Show parts for:
Quick answer: the best power upgrades for your truck
1994-1998 12V
- Fix the basics first: lift pump pressure, a tight front end and fresh fluids.
- Stage 1 towing: an aFe intake and an ATS towing valve body.
- Stage 2: a FASS lift pump, a billet converter, and a built 47RH or 47RE when you tow heavy.
- Fuel changes inside the 12V pump are not covered by a CARB EO, so they are not part of this guide.
1998.5-2002 24V
- Put a fuel pressure gauge on the truck before anything else.
- Stage 1 towing: Edge Juice with Attitude CS2 on a lower level, plus an aFe intake.
- Stage 2 towing: a FASS lift pump, a billet converter and a towing valve body.
- If your block has a "53" casting, stay at Stage 1.
2003-2004
- Stage 1 towing: Edge Evolution CTS3 plus an aFe intake.
- Stage 1 max power: add the S&B elbow and an aFe intercooler.
- Stage 2 towing: a FASS lift pump, a 48RE valve body and converter.
2004.5-2007
- Stage 1 towing: Edge Evolution CTS3 plus an aFe intake.
- Stage 1 max power: add a cat-back exhaust and an intercooler.
- Stage 2 towing: a Fleece in-tank lift pump, a 48RE valve body and converter.
Before you add power
Power makes every weak part weaker. Before you add any, confirm the truck is healthy: no fuel leaks, good lift pump pressure, a tight front end, a clean air filter and fresh transmission fluid. Check the "53" casting number on 1999-2001 blocks, and fix the killer dowel pin on 12V engines.
Plan on gauges from day one. Exhaust gas temperature tells you when to back off while towing, and on the 24V a fuel pressure gauge is the cheapest insurance for the VP44.
Tuning and some performance parts can affect your factory powertrain warranty. Check before you install.
1994-1998 12V
Start with a healthy truck: work through the 1994-1998 12V maintenance guide first.
1998.5-2002 24V
Start with a healthy truck: work through the 1998.5-2002 24V maintenance guide first.
2003-2004
Start with a healthy truck: work through the 2003-2004 maintenance guide first.
2004.5-2007
Start with a healthy truck: work through the 2004.5-2007 maintenance guide first.
Stock power and where the limits are
Every number below is a factory rating at the crank or a typical figure at the wheels, as noted. "Reliable towing target" is where we suggest a truck that tows stops, so the engine, transmission and cooling system all live a long time.
| Years | Stock rating | Transmissions | Reliable towing target | First limit you hit |
|---|---|---|---|---|
| 1994-1998 12V | 160-215 hp, 400-440 lb-ft (higher on manual trucks and on 1996-1998) | 47RH (1994-1995), 47RE (1996-1998), NV4500 5-speed manual | Factory power with better airflow and a stronger transmission | The automatic: it is rated just above stock torque |
| 1998.5-2002 24V | 215-245 hp, 420-505 lb-ft (2001-2002 High Output manual: 245 hp, 505 lb-ft) | 47RE automatic, NV4500 or NV5600 manual | Roughly 250-300 rwhp on stock injectors, depending on the level | The VP44 injection pump and the 47RE |
| 2003-2004 | 235-305 hp, 460-555 lb-ft (2003 standard output: 235 hp; High Output: 305 hp) | 47RE (2003 standard output), 48RE, NV5600 manual | Factory power plus about 60-100 hp with the parts in this guide | The 48RE, then the factory lift pump |
| 2004.5-2007 | 325 hp, 600-610 lb-ft | 48RE, NV5600 manual, G56 manual (from mid 2005) | Factory power plus about 60-100 hp with the parts in this guide | The 48RE |
Stage 1: bolt-ons and tuning
Stage 1 is the bolt-on step: tuning (where a legal option exists), better airflow and the gauges to watch what the engine is doing. The towing build is what we recommend for most trucks. The max power build adds the parts that let the same truck make more power without giving up reliability.
1994-1998 12V
On the 12 valve, almost all of the power comes from changes inside the mechanical injection pump: the fuel plate, the timing and the governor springs. None of those changes is covered by a CARB Executive Order, so we do not recommend them in this guide. Stage 1 on a 12V is about breathing and the transmission: an intake that is listed with an EO, and a towing valve body so the automatic can hold the power it already makes.
Stage 1 towing build
Best for most trucks that tow.
Towing pick
aFe Power 51-72001 Momentum HD Cold Air Intake System with Pro DRY S Filter
aFe Momentum HD intake with a dry filter. Easy to service and a good match for dusty work trucks.
Listed with CARB EO D-550-26
Listed fitment: 1994-2002 Dodge RAM 2500/3500 5.9L Cummins
Check price and fitment
ATS 303-902-2164 47RH Towing Valve Body
ATS towing valve body for the 1994-1995 47RH. Firmer, quicker shifts that cut heat and clutch slip under load.
Listed fitment: 1994-1995 Dodge RAM 2500/3500 5.9L 12V Cummins
Check price and fitment
ATS 303-902-2188 47RE Towing Valve Body
ATS towing valve body for the 1996-1998 47RE.
Listed fitment: 1996-1998 Dodge RAM 2500/3500 5.9L Cummins
Check price and fitmentStage 1 max power build
On a 12V the max power Stage 1 is the oiled version of the same intake. More fuel is not part of a legal Stage 1 on this engine.
aFe Power 50-72001 Momentum HD Cold Air Intake System with Pro 10R Filter
The same aFe Momentum HD intake with an oiled Pro 10R filter for a little more airflow.
Listed with CARB EO D-550-26
Listed fitment: 1994-2002 Dodge RAM 2500/3500 5.9L Cummins
Check price and fitment1998.5-2002 24V
The 24V's VP44 pump is electronically controlled, so a plug-in module can add fuel without touching the pump. The Edge Juice with Attitude CS2 is covered by CARB EO D-541-16 (part 31400 for 1998.5-2000, 31401 for 2001-2002) and includes a monitor for exhaust gas temperature and fuel pressure. Before you add any power, put a fuel pressure gauge on the truck: the VP44 needs steady supply pressure, and a weak lift pump is the number one reason they fail.
Stage 1 towing build
Best for most trucks that tow.
1998.5-2000
Edge 31400 Juice w/Attitude CS2
Edge Juice with Attitude CS2 for 1998.5-2000 trucks. Selectable power levels plus a monitor; run the lower levels when towing. Covered by the EO with Edge's preloaded levels.
Listed with CARB EO D-541-16
Listed fitment: 1998.5-2002 Dodge RAM 2500/3500 5.9L 24V Cummins
Check price and fitment
2001-2002
Edge 31401 Juice w/Attitude CS2
Edge Juice with Attitude CS2 for 2001-2002 trucks, covered by the same EO.
Listed with CARB EO D-541-16
Listed fitment: 2001-2002 Dodge RAM 2500/3500 5.9L Cummins
Check price and fitmentaFe Power 51-72001 Momentum HD Cold Air Intake System with Pro DRY S Filter
aFe Momentum HD intake with a dry filter.
Listed with CARB EO D-550-26
Listed fitment: 1994-2002 Dodge RAM 2500/3500 5.9L Cummins
Check price and fitment
Edge 38503 Dash Pod
Edge dash pod that mounts the CS2 screen cleanly on the dash.
Listed fitment: 1998.5-2002 Dodge RAM 2500/3500 5.9L 24V Cummins
Check price and fitmentStage 1 max power build
Adds to the towing build for more power.
S&B 76-1007 Intake Elbow
S&B intake elbow that smooths airflow into the intake manifold.
Listed with CARB EO D-590-7
Listed fitment: 1998.5-2002 Dodge RAM 2500/3500 5.9L 24V Cummins
Check price and fitment
AutoMeter 7095 Ultra Lite Triple Gauge Pillar Kit
AutoMeter triple gauge pillar for boost, exhaust temperature and fuel pressure.
Listed fitment: 1998-2002 Dodge RAM 2500/3500
Check price and fitment2003-2004
The 2003-2004 common rail takes tuning well. The Edge Evolution CTS3 is covered by CARB EO D-802-13 for 2003-2007 5.9L trucks and includes a full monitor, so it handles tuning and gauges in one part. Add an intake listed with an EO and you have a complete Stage 1.
Stage 1 towing build
Best for most trucks that tow.
Towing pick
Edge 85401-301 Evolution CTS3
Edge Evolution CTS3 programmer with a 5 inch touch screen monitor. Choose a towing level for daily use.
Listed with CARB EO D-802-13
Listed fitment: 2003-2012 Dodge RAM 2500/3500 5.9L/6.7L Cummins
Check price and fitment
aFe Power 50-72002 Momentum HD Cold Air Intake System with Pro 10R Filter
aFe Momentum HD intake with an oiled Pro 10R filter.
Listed with CARB EO D-550-26
Listed fitment: 2003-2007 Dodge RAM 2500/3500 5.9L Cummins
Check price and fitmentStage 1 max power build
Adds to the towing build for more power.
S&B 76-1004 Intake Elbow
S&B intake elbow for smoother airflow into the head.
Listed with CARB EO D-590-7
Listed fitment: 2003-2007 Dodge RAM 2500/3500 5.9L Cummins
Check price and fitment
aFe 46-20011 BladeRunner GT Series Intercooler
aFe BladeRunner GT intercooler. Cooler intake air means lower exhaust temperatures under load.
Listed with CARB EO D-550-7
Listed fitment: 2003-2007 Dodge RAM 2500/3500 5.9L Cummins
Check price and fitment
AutoMeter 8544 Factory Match 2-1/16 inch 0-1600F Pyrometer Kit
AutoMeter pyrometer kit if you want a dedicated exhaust temperature gauge.
Listed fitment: 2003-2009 Dodge RAM 2500/3500
Check price and fitment2004.5-2007
The 2004.5-2007 "600" engine is the strongest 5.9. The Edge Evolution CTS3 is covered by CARB EO D-802-13 for these trucks, and its monitor shows the exhaust temperature you need to watch while towing. Pair it with an intake listed with an EO and a cat-back exhaust that keeps the factory converter.
Stage 1 towing build
Best for most trucks that tow.
Towing pick
Edge 85401-301 Evolution CTS3
Edge Evolution CTS3 programmer and monitor. Run a towing level when hooked up.
Listed with CARB EO D-802-13
Listed fitment: 2003-2012 Dodge RAM 2500/3500 5.9L/6.7L Cummins
Check price and fitmentaFe Power 50-72002 Momentum HD Cold Air Intake System with Pro 10R Filter
aFe Momentum HD intake with an oiled Pro 10R filter.
Listed with CARB EO D-550-26
Listed fitment: 2003-2007 Dodge RAM 2500/3500 5.9L Cummins
Check price and fitmentStage 1 max power build
Adds to the towing build for more power.
Diamond Eye K4234A 4 inch Aluminized Cat Back No Tip Exhaust
Diamond Eye 4 inch aluminized cat-back exhaust. Keeps the factory catalytic converter.
Listed fitment: 2004.5-2007 Dodge RAM 2500/3500 5.9L Cummins
Check price and fitmentS&B 76-1004 Intake Elbow
S&B intake elbow.
Listed with CARB EO D-590-7
Listed fitment: 2003-2007 Dodge RAM 2500/3500 5.9L Cummins
Check price and fitmentaFe 46-20011 BladeRunner GT Series Intercooler
aFe BladeRunner GT intercooler for cooler intake air and lower exhaust temperature.
Listed with CARB EO D-550-7
Listed fitment: 2003-2007 Dodge RAM 2500/3500 5.9L Cummins
Check price and fitmentStage 2: fuel, turbo and the parts that support them
Stage 2 adds fuel supply and airflow, and the supporting parts that keep the extra power reliable. On most trucks the transmission has to be part of Stage 2, so it is included here.
1994-1998 12V
Stage 2 on a 12V is the fuel supply and the drivetrain. A frame-mounted lift pump with water separation feeds the injection pump clean fuel at steady pressure, and a billet converter and built transmission let the truck tow hard for a long time. The FASS pump below has no CARB EO; it does not change engine calibration, but California rules still apply.
Stage 2 towing build
Fuel supply and drivetrain first.
Towing pick
FASS TSD10180F140G Titanium Signature Series 140GPH Fuel Lift Pump
FASS 140 gph lift pump with added filtration and water separation for the 12V.
No CARB EO: not legal for sale or use in California
Listed fitment: 1994-1998 Dodge RAM 2500/3500 5.9L 12V Cummins
Check price and fitment
ATS 302-950-2164 47RH 47RE 48RE Five Star 1300-1500 RPM Stall Torque Converter
ATS Five Star torque converter with a low stall that suits towing.
Listed fitment: 1994-2007 Dodge RAM 2500/3500 5.9L Cummins
Check price and fitmentStage 2 max power build
Adds to the towing build for more power.
ATS 309-912-2164 47RH Stage 1 Transmission Package
ATS Stage 1 transmission package for 1994-1995 47RH trucks, 2WD. A complete built transmission with converter.
Listed fitment: 1994-1995 Dodge RAM 2500/3500 5.9L Cummins 2WD
Check price and fitment
ATS 309-912-2188 47RE Stage 1 Transmission Package
ATS Stage 1 transmission package for 1996-1998 47RE trucks, 2WD.
Listed fitment: 1996-1998 Dodge RAM 2500/3500 5.9L Cummins 2WD
Check price and fitment
ATS 309-914-2188 47RE Stage 1 Transmission Package
ATS Stage 1 transmission package for 1996-1998 47RE trucks, 4WD.
Listed fitment: 1996-1998 Dodge RAM 2500/3500 5.9L Cummins 4WD
Check price and fitment
ATS 302-930-2164 47RH 47RE 48RE Triplelok Torque Converter
ATS Triplelok triple-disc torque converter for more holding power.
Listed fitment: 1994-2007 Dodge RAM 2500/3500 5.9L Cummins
Check price and fitment1998.5-2002 24V
On a 24V, Stage 2 starts with the lift pump. A stronger, filtered pump protects the VP44, and the transmission has to be built before you tow at Stage 1 power for long. If your block has a "53" cast into the side, do not go past Stage 1: those blocks can crack, and added load raises the risk.
Stage 2 towing build
Fuel supply and drivetrain first.
Towing pick
FASS TSD08100G Titanium Signature Series 100GPH Fuel Lift Pump
FASS 100 gph lift pump with filtration and water separation. Plenty for a 24V at Stage 1 and 2 power.
No CARB EO: not legal for sale or use in California
Listed fitment: 1998.5-2004 Dodge RAM 2500/3500 5.9L Cummins
Check price and fitmentATS 302-950-2164 47RH 47RE 48RE Five Star 1300-1500 RPM Stall Torque Converter
ATS Five Star torque converter with a low stall that suits towing.
Listed fitment: 1994-2007 Dodge RAM 2500/3500 5.9L Cummins
Check price and fitment
ATS 303-902-2218 47RE Towing Valve Body
ATS towing valve body for late 1998 and early 1999 47RE trucks.
Listed fitment: 1998.5-1999 Dodge RAM 2500/3500 5.9L 24V Cummins
Check price and fitment
ATS 303-902-2237 47RE Towing Valve Body
ATS towing valve body for late 1999-2002 47RE trucks.
Listed fitment: 1999.5-2002 Dodge RAM 2500/3500 5.9L Cummins
Check price and fitmentStage 2 max power build
Adds to the towing build for more power.
FASS TSD08165G Titanium Signature Series 165GPH Fuel Lift Pump
FASS 165 gph lift pump for extra fuel supply headroom.
No CARB EO: not legal for sale or use in California
Listed fitment: 1998.5-2004 Dodge RAM 2500/3500 5.9L Cummins
Check price and fitment
ATS 309-912-2237 47RE Stage 1 Transmission Package
ATS Stage 1 47RE transmission package for late 1999-2002 trucks, 2WD.
Listed fitment: 1999.5-2002 Dodge RAM 2500/3500 5.9L Cummins 2WD
Check price and fitment
ATS 309-914-2237 47RE Stage 1 Transmission Package
ATS Stage 1 47RE transmission package for late 1999-2002 trucks, 4WD.
Listed fitment: 1999.5-2002 Dodge RAM 2500/3500 5.9L Cummins 4WD
Check price and fitment
ARP 247-4202 Pro Series Head Stud Kit
ARP head studs. Recommended once you run higher boost or tow at the top of the range.
Listed fitment: 1998.5-2018 Dodge RAM 2500/3500 5.9L/6.7L Cummins
Check price and fitment2003-2004
The 2003-2004 block-mounted lift pump fails often, and the 7 micron factory filter is the only filtration the injectors get. Stage 2 adds a frame-mounted pump with better filtration and builds the 48RE. We do not list injector or turbo upgrades for these years because none we carry is covered by a CARB EO.
Stage 2 towing build
Fuel supply and drivetrain first.
Towing pick
FASS TSD08100G Titanium Signature Series 100GPH Fuel Lift Pump
FASS 100 gph lift pump with filtration and water separation for 2003-2004 trucks.
No CARB EO: not legal for sale or use in California
Listed fitment: 1998.5-2004 Dodge RAM 2500/3500 5.9L Cummins
Check price and fitment
ATS 303-902-2272 48RE Towing Valve Body
ATS towing valve body for the 2003-2004 48RE.
Listed fitment: 2003-2004 Dodge RAM 2500/3500 5.9L Cummins
Check price and fitmentATS 302-950-2164 47RH 47RE 48RE Five Star 1300-1500 RPM Stall Torque Converter
ATS Five Star torque converter.
Listed fitment: 1994-2007 Dodge RAM 2500/3500 5.9L Cummins
Check price and fitmentStage 2 max power build
Adds to the towing build for more power.
FASS TSD08165G Titanium Signature Series 165GPH Fuel Lift Pump
FASS 165 gph lift pump for extra supply headroom.
No CARB EO: not legal for sale or use in California
Listed fitment: 1998.5-2004 Dodge RAM 2500/3500 5.9L Cummins
Check price and fitmentATS 302-930-2164 47RH 47RE 48RE Triplelok Torque Converter
ATS Triplelok triple-disc torque converter for more holding power.
Listed fitment: 1994-2007 Dodge RAM 2500/3500 5.9L Cummins
Check price and fitmentARP 247-4202 Pro Series Head Stud Kit
ARP head studs, recommended at the top of the towing range.
Listed fitment: 1998.5-2018 Dodge RAM 2500/3500 5.9L/6.7L Cummins
Check price and fitment2004.5-2007
2005 and newer trucks moved the lift pump into the tank, and those pumps still fail. Stage 2 adds a better lift pump and builds the 48RE. 2004.5 trucks (2004 model year) still have the block-mounted pump: call our sales team for the right pump for those trucks.
Stage 2 towing build
Fuel supply and drivetrain first.
Towing pick
Fleece FPE-34560 170GPH PowerFlo In-Tank Lift Pump
Fleece PowerFlo in-tank lift pump for 2005-2009 trucks. A direct upgrade of the factory pump.
Listed with CARB EO D-834-10
Listed fitment: 2005-2009 Dodge RAM 5.9L/6.7L 2500/3500 Cummins
Check price and fitment
ATS 303-902-2290 48RE Towing Valve Body
ATS towing valve body for 2004.5-2007 48RE trucks.
Listed fitment: 2004.5-2007 Dodge RAM 2500/3500 5.9L Cummins
Check price and fitmentATS 302-950-2164 47RH 47RE 48RE Five Star 1300-1500 RPM Stall Torque Converter
ATS Five Star torque converter.
Listed fitment: 1994-2007 Dodge RAM 2500/3500 5.9L Cummins
Check price and fitmentStage 2 max power build
Adds to the towing build for more power.
FASS TSD07100G Titanium Signature Series 100GPH Lift Pump
FASS 100 gph frame-mounted lift pump with filtration for 2005 and newer trucks, an alternative to the in-tank pump.
No CARB EO: not legal for sale or use in California
Listed fitment: 2005-2018 & 2021-2024 RAM 2500/3500 5.9L/6.7L Cummins
Check price and fitmentATS 302-930-2164 47RH 47RE 48RE Triplelok Torque Converter
ATS Triplelok triple-disc torque converter.
Listed fitment: 1994-2007 Dodge RAM 2500/3500 5.9L Cummins
Check price and fitmentARP 247-4202 Pro Series Head Stud Kit
ARP head studs for the top of the towing range.
Listed fitment: 1998.5-2018 Dodge RAM 2500/3500 5.9L/6.7L Cummins
Check price and fitmentTransmission and clutch
1994-1998 12V
The 47RH and 47RE are the weak link behind a 12V. DieselHub puts their limit at about 450 lb-ft at the input, which is barely above a stock 1996-1998 truck. If you tow heavy, a towing valve body and a billet converter are the first upgrades, and a built transmission is the long-term fix. On NV4500 manual trucks, the clutch is the first part to give up when you add load.
South Bend Clutch 13125-OFER 13 inch Half Organic Half FeRAMic Clutch Kit
South Bend 13 inch half organic, half feramic clutch for NV4500 trucks. Smooth engagement with more holding power.
Listed fitment: 1989-2005 Dodge RAM 2500/3500 5.9L Cummins
Check price and fitment1998.5-2002 24V
The 47RE behind a 24V was rated at roughly the engine's stock torque. Stage 1 power on a truck that tows calls for at least a billet converter and a valve body; Stage 2 calls for a built transmission. Manual trucks need a stronger clutch at Stage 1.
South Bend Clutch 13125-OFER 13 inch Half Organic Half FeRAMic Clutch Kit
South Bend half organic, half feramic clutch for NV4500 trucks.
Listed fitment: 1989-2005 Dodge RAM 2500/3500 5.9L Cummins
Check price and fitment
South Bend Clutch 1947-OFE Organic/Feramic Clutch Kit with Flywheel
South Bend organic and feramic clutch with flywheel for NV5600 trucks.
Listed fitment: 2000.5-2005.5 Dodge RAM 2500/3500 5.9L Cummins
Check price and fitment2003-2004
The 47RE and 48RE are the limit on these trucks. Even a towing Stage 1 should get a valve body and converter. Past about 400 rwhp, the transmission needs a full build with a billet input shaft and upgraded clutches and bands. NV5600 manual trucks need a stronger clutch at Stage 1.
RevMax 478-703 48RE High Performance Rebuild Kit (GPZ Clutches)
RevMax 48RE high performance rebuild kit with upgraded clutches, for a professional rebuild.
Listed fitment: 2003-2007 Dodge RAM 2500/3500 5.9L Cummins
Check price and fitmentSouth Bend Clutch 1947-OFE Organic/Feramic Clutch Kit with Flywheel
South Bend organic and feramic clutch with flywheel for NV5600 trucks.
Listed fitment: 2000.5-2005.5 Dodge RAM 2500/3500 5.9L Cummins
Check price and fitment2004.5-2007
The 48RE is the limit. A towing Stage 1 needs a valve body and converter; Stage 2 or about 450 rwhp calls for a built transmission. Manual trucks need a stronger clutch at Stage 1.
RevMax 478-703 48RE High Performance Rebuild Kit (GPZ Clutches)
RevMax 48RE high performance rebuild kit, for a professional rebuild.
Listed fitment: 2003-2007 Dodge RAM 2500/3500 5.9L Cummins
Check price and fitmentSouth Bend Clutch 1947-OFE Organic/Feramic Clutch Kit with Flywheel
South Bend clutch with flywheel for NV5600 trucks.
Listed fitment: 2000.5-2005.5 Dodge RAM 2500/3500 5.9L Cummins
Check price and fitment
South Bend Clutch G56-OR-HD Full HD Organic Clutch Kit
South Bend heavy-duty organic clutch for 2005.5 and newer G56 trucks.
Listed fitment: 2005-2018 Dodge RAM 2500/3500/4500 5.9L/6.7L 2500/3500 Cummins
Check price and fitmentSafe towing temperatures
Added power means added heat. These are the numbers to watch on your gauges while towing. They are sustained readings, not short spikes on a hill.
| Reading | Normal while towing | When to act |
|---|---|---|
| EGT (probe before the turbo) | Under about 1,200°F sustained | Back off or downshift if it stays above 1,250°F. On trucks with a particulate filter, sustained heat above that risks the filter. |
| EGT (probe after the turbo) | Reads about 200-300°F lower than a pre-turbo probe | Know which probe your gauge uses before you set an alarm. |
| Transmission fluid | 170-200°F | Act at 210-225°F sustained: slow down, downshift, add cooling. |
| Coolant | 195-220°F | Act if it stays over 225°F. |
| Engine oil | 210-240°F | Act at 250°F or more, sustained. |
Emissions and legal fitment
Every part in this guide keeps your truck's factory emissions equipment in place and working. Where a part is listed with a California Air Resources Board Executive Order (CARB EO), the card says so. That EO exempts the part from California's tampering law (Vehicle Code 27156) for the vehicles it lists. An EO covers only the exact part numbers, years and engines it lists, and an EO for a tuner covers only the maker's preloaded tunes: a custom tune is not covered. Each EO covers its part by itself; CARB has not evaluated combinations of tuned parts. Parts marked "No CARB EO" are not legal for sale or use in California on pollution-controlled vehicles. Exhaust that bolts on behind the catalytic converter or particulate filter generally does not need an EO, but local noise rules still apply.
1994-1998 12V
The 12V has no EGR or particulate filter, but some trucks left the factory with a catalytic converter. Check the emissions label under the hood. If your truck has a converter, keep it. Mechanical fuel changes to the injection pump are not covered by any CARB EO.
1998.5-2002 24V
Most 24V trucks have no EGR or particulate filter. Some have a catalytic converter: check the emissions label and keep the converter if it is there. The Edge CS2 is listed with a CARB EO only when used with its preloaded settings.
2003-2004
2003-2004 trucks have no EGR or particulate filter, and most have a catalytic converter. Keep it in place. The Edge CTS3, aFe intake, S&B elbow and aFe intercooler in this guide are listed with CARB EOs.
2004.5-2007
2004.5-2007 trucks have a catalytic converter and no particulate filter. Keep the converter. The cat-back exhaust in this guide bolts on behind it. The Edge CTS3 is covered by CARB EO D-802-13 when used with its preloaded tunes.
Shop parts for your truck
1994-1998 12V
1998.5-2002 24V
2003-2004
2004.5-2007
Not sure which parts your truck needs?
Alligator's sales team helps 5.9 Cummins owners plan power upgrades every day. Tell us your year, transmission, what you tow and how far you want to go, and we will build a parts list that fits and flag anything not covered by a CARB EO.
Call 208-719-7400Send us a messageFrequently asked questions
How much power can a 5.9 Cummins make reliably while towing?
It depends on the year. A 24V with a healthy lift pump and an Edge module makes roughly 250-300 rwhp on stock injectors, depending on the level. A 2003-2007 common rail gains about 60-100 hp with the tuner, intake and supporting parts in this guide, as long as the transmission is ready for it.
What is the first upgrade for a 5.9 that tows?
On automatics, the transmission: a towing valve body and a billet torque converter. The 47RE and 48RE were rated close to stock torque, so they are the first part to suffer when you add power.
Why doesn't this guide include fuel plates or timing changes for the 12V?
Those changes alter the injection pump's fuel calibration and no CARB Executive Order covers them. This guide sticks to parts that are listed with an EO or that do not affect emissions.
Do I need a lift pump before adding power to a 24V?
Yes. The VP44 is cooled by the fuel that flows through it, and low supply pressure is the most common reason it fails. A filtered lift pump and a fuel pressure gauge come first.
Is the Edge Evolution CTS3 legal in California on a 5.9?
Yes for 2003-2007 5.9L trucks: it is covered by CARB EO D-802-13 when it is used with Edge's preloaded tunes. A custom tune is not covered.
Do I need head studs?
Not at Stage 1. They are cheap insurance when you run higher boost or tow at the top of the Stage 2 range on 1998.5 and newer engines.
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