2003-2004 Dodge 5.9L Cummins Exhaust Accessories

Exhaust accessories for the 2003-2004 Ram 5.9L Cummins

On this platform the accessory list is short and practical: exhaust brakes and the parts that control them, manifold gasket and bolt kits, turbo-flange gaskets, and tips and stacks for the end of the pipe. The factory exhaust on the common-rail 5.9L Cummins runs 3.5-inch pipe ahead of the muffler and 4-inch pipe from the muffler to the tailpipe, which is why most of the tips here have a 4-inch inlet.

Exhaust brakes

An exhaust brake is a valve that raises backpressure on demand, turning the engine into a brake and saving your service brakes on long descents. Kits for these trucks come in versions for manual transmissions and for 47RE/48RE automatics. The 2004.5-2007 trucks use different kits because the turbo outlet and downpipe changed with the HE351CW turbo, so buy by build date, not just model year.

Tips and finishing parts

Aftermarket systems are sold with polished or black tips, and this is where you pick the look. Match the tip inlet to your pipe, then choose outlet size and cut. If you are adding a pyrometer while the exhaust is apart, remember the probe belongs in the manifold or the turbo up-pipe, not downstream.

What we carry

These accessories sit inside our larger exhaust section:

• Exhaust brakes and controls: BD Diesel remote-mount exhaust brakes, including the 1027338 4-inch brake listed for 2003-2005 Cummins, the 1030900 manual-transmission lever switch, and the 1030398 Torqloc torque converter control system listed for 1994-2004 Cummins.
• Tips: MBRP tips with 4-inch inlets and 4-inch through 8-inch outlets in rolled, straight, angle and turndown cuts, single and dual wall, plus a black hex tip; PPE 3-inch and 4-inch stainless tips; and a Mishimoto 6-inch polished angled tip.
• Clamps and wrap: the BD 1405926 V-band clamp and the Mishimoto MMTW-235 heat wrap set.
• Head sets: Mahle HS54556 and HS54557, listed for 2003-2007 5.9L Cummins.

Fitment notes

Everything here is for the Dodge Ram 2500 and 3500, not the Ram 1500. Measure your tailpipe before buying a tip; the stock section is 4-inch, but an aftermarket system may be bigger. Exhaust brake parts are year-specific across the 2004.5 change, so confirm your build date before ordering. Verify by VIN with the fitment checker, or call the shop and we will sort it out.

Frequently asked questions

Which exhaust tip fits a stock 2003-2004 Ram 2500 or 3500?

The factory pipe from the muffler back is 4-inch, so a tip with a 4-inch inlet is the starting point. Then pick the outlet size and cut you like; the MBRP tips here run from 4-inch to 8-inch outlets. If your truck already has an aftermarket system, measure the pipe first.

Do I need anything besides the exhaust brake itself?

Match the kit to your transmission, since kits for these trucks come in manual and 47RE/48RE automatic versions. BD lists a manual-transmission lever switch and the Torqloc torque converter control system alongside its brakes here. Check the brake's product page for what your setup calls for.

Where should a pyrometer probe go if I am working on the exhaust anyway?

In the exhaust manifold or the turbo up-pipe, ahead of the turbo. A probe further downstream reads lower than what the engine is seeing. If you have the exhaust apart for a brake or manifold job, that is a good time to plan the probe location.

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.