1994-1998 Dodge 5.9L Cummins Tools

Tools for the 1994-1998 RAM 5.9L Cummins

These are second-generation trucks, sold as the Dodge Ram 2500 and 3500 in WS, ST and Laramie SLT trim. The 5.9L Cummins 12-valve under the hood is a mechanical engine. The Bosch P7100 inline injection pump has no electronics, cold starts lean on a grid heater instead of glow plugs, and most service is done with hand tools: setting valve lash, priming the lift pump, adjusting transmission bands. You won't plug in a scan tool for any of that. A good socket set covers most of it. This page covers the specialty pieces the common jobs call for, plus the bench gear that makes the work go smoother.

Jobs that call for special tools

No failure pattern belongs to the tools themselves. The reason to own the right tool is doing the job to spec: the right lash, the right torque, the right band setting. Here is what each common job takes.

• Valve lash. An engine barring tool to rotate the engine, the timing pin to find cylinder 1 TDC, and feeler gauges in 0.010 and 0.020 in. The adjuster locknuts and the valve cover bolts both go back at 18 ft-lb.
• KDP fix. The killer dowel pin tab job at the front gear housing takes 10mm, 13mm, 15mm and 16mm sockets, a 1/2-in. breaker bar for the damper bolts (92 ft-lb), a gasket scraper, and the seal driver and crank seal starter that come in the kit. An experienced shop does it in about two hours.
• Lift pump priming. The hand primer takes hundreds of strokes. A broom handle fitted with a 3/4-in. PVC coupling saves your thumb. If you are replacing the pump, a longer starter bolt makes it possible to install the new one from above.
• Transmission bands. The 47RH and 47RE need the bands set every 24,000 miles. That takes an inch-pound torque wrench set to 72 in-lb and the right back-off count for your model year.

Job-specific tools vs. general shop gear

Some of what we carry is built for this engine and nothing else. The XDP XD312 and the Hamilton Cams spring compressor are made for the 12-valve head, which runs two valves per cylinder. The XDP XD134 injection pump gear puller is listed for 1989-2018 5.9L and 6.7L Cummins, so it stays useful if your next truck is newer. The rest is general shop gear that earns its space on any diesel: thread chasers, a grease gun adapter, a quick disconnect tool kit, a tool tray and a solid bench. If you do one or two jobs a year, buy the tool for the job in front of you. If you plan to keep the truck, the bench and the thread chasers pay off on every project after.

What we carry

• XDP: the XD312 valve spring compressor for 12-valve engines, the XD134 injection pump gear puller, and thread cleaning chasers in M8x1.25, M12x1.5, M12x1.75 and M16x2.0 for cleaning up threads before you torque.
• Hamilton Cams: a 12 valve spring compressor for 1989-1998 5.9L Cummins.
• Calibrated Power Solutions: the Stealth Boost Tester HD regulator, a Holset compressor inlet adapter, and an inlet adapter for S300, S400, S400R and S500 turbos, for pressure-testing the intake side.
• Wehrli Custom Fabrication: modular steel work benches in 32 x 48, 32 x 72 and 32 x 90 in.
• Merchant Automotive: a right angle grease gun adapter and a quick disconnect tool kit.
• S&B: a flexible silicone tool tray that keeps sockets and bolts in one place.

Fitment notes

Check the listed years on every tool. The spring compressors are built for 1989-1998 12-valve engines. 1998 is a split year: Dodge switched to the 24-valve ISB with the VP44 pump partway through the model year, so a 1998 truck can have either engine. Look at the pump. A P7100 inline pump with a mechanical shutoff solenoid on top is a 12-valve; a VP44 rotary pump with a wiring harness is a 24-valve. The Holset boost tester adapter is listed for 1998-2018 5.9L and 6.7L Cummins, so confirm it matches the turbo on your truck. The S300/S400-family adapter is for trucks already running one of those turbos. Benches, trays, chasers and grease tools fit any truck.

Frequently asked questions

What do I need to set valve lash on a 12-valve Cummins?

An engine barring tool to turn the engine over, the timing pin to locate cylinder 1 TDC, and feeler gauges in 0.010 and 0.020 in. Torque the locknuts and the valve cover bolts to 18 ft-lb when you button it up.

Which tools does the KDP fix take?

Plan on 10mm, 13mm, 15mm and 16mm sockets, a 1/2-in. breaker bar for the damper bolts, and a gasket scraper. The damper bolts go back at 92 ft-lb. The seal driver and crank seal starter come with the tab kit, and an experienced shop does the job in about two hours.

What band settings does my 47RH or 47RE need?

Torque each band adjuster to 72 in-lb, then back it off. Front band: 2.5 turns on 1994, 2.875 turns on 1995-1996, 1.875 turns on 1997 and later. Rear band: 2 turns through 1996, 3 turns from 1997. Repeat every 24,000 miles.

Is there an easier way to prime the lift pump?

Yes. The primer button takes hundreds of strokes, so slip a 3/4-in. PVC coupling over a broom handle and use that to work it. If the pump itself is being replaced, a longer starter bolt makes it possible to install the new pump from above.

Which turbos does the boost tester adapter fit?

The Holset compressor inlet adapter is listed for 1998-2018 5.9L and 6.7L Cummins. A separate inlet adapter covers S300, S400, S400R and S500 turbos and pairs with the Stealth Boost Tester HD regulator. If your truck still runs its factory Holset, check the adapter's fitment against your turbo or call us before ordering.

Not sure what fits? Call the shop at the number in the header, or use the fitment checker on any product page. We install everything we sell.