2004.5-2007 Dodge 5.9L Cummins Valve Covers

Valve covers on the 2004.5-2007 RAM 5.9L Cummins

The top of this engine changed in 2006. On 2003-2005 engines, a black plastic breather cover sits on an aluminum rocker housing. The breather assembly is separate, held by four 10 mm bolts with O-rings, and the injector wiring passes through three pass-through connectors. On 2006-2007 engines, Cummins switched to a one-piece molded plastic valve cover with an integral breather filter and a single multi-wire injector connector. Valve cover bolts torque to 18 ft-lb. Under the cover sit the rockers, pushrods and valve bridges of a solid-lifter valvetrain with four valves per cylinder.

Why the cover comes off

On this engine the valve cover comes off more often than owners expect. The exhaust rockers must come off for injector replacement, so every injector job starts with pulling the cover. The valve lash check is due at 150,000 miles, with a reset to 0.010 in on the intake and 0.020 in on the exhaust. Rocker bolts torque to 27 ft-lb when they go back on. Each of those jobs is a reason to have a fresh valve cover gasket, rocker box gasket and grommets on the bench before you start.

Stock replacement vs. upgrade

For most trucks, a factory-style gasket is all the job needs. Genuine Cummins and Mahle gaskets match the original design for each year range, and Dorman's 904-360 set bundles the valve cover and rocker box gaskets for 2003-2007. If you want metal on top, billet aluminum covers are the upgrade: WCFab's WCF100366 for 2006 and later engines, and G&R Diesel covers for both year ranges. XDP's HD billet oil fill cap replaces the factory cap. If you are doing a bigger top-end job, Mahle head sets bundle the gaskets for pulling the head.

What we carry

Genuine Cummins: the 3954324 valve cover gasket for 2003-2005, the 5367847 valve cover gasket with wiring harness for 2006 and later, the 3963379 rocker box gasket and the 3974981 rocker box housing. Mahle: VS50416 and VS50543 valve cover gaskets, the VS50419 rocker box gasket, GS33799 valve cover grommets and the HS54556 and HS54557 head sets. Dorman: the 904-360 valve cover and rocker box gasket set. Billet covers come from WCFab and G&R Diesel, and XDP supplies the billet oil fill cap. The rest of the engine is in our Cummins parts section.

Fitment notes

Year matters on this page. For 2003-2005 engines, use the Cummins 3954324 or Mahle VS50416 valve cover gasket and the G&R Diesel GRD59CM3005 billet cover. For 2006-2007, use the Cummins 5367847 gasket with harness or the Mahle VS50543, the WCFab WCF100366 or G&R Diesel GRD59CM3009 cover, and the 3974981 rocker box housing. The rocker box gaskets, the Mahle grommets and the oil fill cap span both ranges. On 2007 trucks, confirm the engine is the 5.9L, because the 6.7L took over partway through the model year. Verify by VIN.

Frequently asked questions

Why are there different valve cover gaskets for 2005 and 2006 trucks?

Cummins changed the design for 2006. Earlier engines use a separate breather on the aluminum rocker housing with three pass-through injector connectors, while 2006-2007 engines use a one-piece molded plastic cover with an integral breather and a single multi-wire connector. The gaskets and harness are different, so order by year.

What do the valve cover and rocker bolts torque to?

Valve cover bolts torque to 18 ft-lb and rocker bolts to 27 ft-lb on the 2003 and later common-rail 5.9L. If the rockers came off for an injector job or a lash check, confirm lash at 0.010 in intake and 0.020 in exhaust before the cover goes back on.

When do I need to take the valve cover off?

Any injector replacement, because the exhaust rockers must come off for that job, and the valve lash check due at 150,000 miles. Have a new gasket and grommets on hand before you start so the truck is not sitting while you wait on parts.

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.