Engine changes from 05 to 06
 

Folks, was there any changes made to the stock 5.9s from the model yr. 05 to 06? Was there any changes to the motors mid yr. 06?
thx.

I think the Marketing Department called the '05 motor 325hp/600ft and the '06 motor 325hp/610ft.

Cummins considers them the same.

The only differance I have seen between my 06 and my partners 05 is the ends of the intercooler, his are like a plastic and mine are aluminium, or metal. the engine specs seem the same 325hp 610tc

I believe there was a valve seat material change done to withstand the higher egt's.

thanks guys, I'm shopping to update from my 03 and am looking at the differences between 05 & 06, auto trannies too
There seems to be more selection in the 06s out there right now.

HvyTrkMech is right, the valve lash on 05 is .020 on exh and on my 06 it is .026
The Valve cover looks a little different if I remember. I don't think much difference to amt to anything, but I'm just a shadetree.

Tim im pretty sure that change was when they went to the 04.5 engine.....from the 03-early 04 design.

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Cool, I knew it was around 05 time line just not exactly sure.

Thanks for the info.[coffee]

Don M says they redesigned the heads to flow more -- was in another post by a sled pulling rig who burnt his pistons...

my '05 has the 325/610..

The plastic intercooler was changed in mid 05. My service manual has my 05 as 325/600.

i think they might have changed something w/ the injector pulses...but i'm not sure. all i know is that if you put my buddies 06 beside my 05...you hear the engine noise a lot more from mine than his. granted, i have about 11k more miles on mine than he has. but i'm curious on the differences as well. i know he has to rebuild his motor and if he gets a used motor, he has to use one from an 06-07.

You may want to include early prodution 2007 in your search as they still had the 5.9L and 4 speed tranny. They seem to have a pretty high demand, too, since its the last year model for the 5.9. pcm

Yup. 07 5.9 is basically the same as an 06, except with different taillights and headlights. Thats what I have

There has been several changes to valves and seats to handle the emissions and added EGT's. The 04.5-05 were a little different than the 03-04 thne in 06 it was modified slightly again and the head air flow chnaged to help address the extra temps.

04.5 were 326\600 and 05 was 325\610.

Injectors are the same from 04.5-07, only the software differs a bit in how the fuel management is implemented.

The 06+ is a CANBUS system with a TIPM and lot more reliance on electronic controls. The TIPM's are a pain if you pop the equivalent of a breaker you have to have reset usinng STARSCAN. You get 3 resets and you replace the TIPM. Not cheap, if you pull trailers and breakout box is a good investment.

The transmissin controls are much better in the 06-07 if you like autos, pretty much the same for the manuals. DMF is the weal link on all of them.

Only the first hal of 05 had plastic intercooler, mid year they went back to aluminum. Rads are still plastic tanks in all of them.

i think my 05 was right in the middle, it has the plastice end caps and the g56. lol

Im surprized we haven't heard more about this. With the exception of Don M's comment in another post...and your comment here I don't recall ever hearing of any differences in the heads from 04.5 thru early 07s.

You would also think that if the 06's have better flowing heads, that that would translate into more power. I don't see that based on dyno numbers or track times....of 06's regularly beating an 04.5 or 05 truck. You hear it all the time regarding the 03 and early 04s, however.

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Air doesn't make power, fuel does. The flow differences are minor and you would probably only see small differences when you push the envelope. The valve\valvel seat material changes were to address the tendency of the early 600's to drop seats.

Most of these changes are not common knowledge unless the heads have been flowed, access to the technical bulletins from Dodge or Cummins on the small material changes, etc. In other words its not big performance news. [coffee]

I too haven't read about this, and was under the impression 04.5-07 was the same. In fact my dad's 06 runs hotter than my 05. The Press releases talk about the valve/valve seat change in materiel in 04.5 to handle the higher (1450* continuous rating) that the 600 has to meet NOx emissions without an EGR valve.

I would like to see some more info on this...

The only differences I have verified are the electronics/wiring, and valve cover.

Head porting doesnt make as much difference on a turbo motor as it does on normally aspirated, I owned a 04.5 and drove it daily for three yrs, traded in for my 06, which I have also driven daily for 3.5 yrs. I noticed no differance in engine power, egt, boost, fuel pressure. But I did seem to get better fuel mileage on my brand new 06 motor, than I did with my 50kmi 04.5. And I still get better than I ever did with the 04.5 by a little but I run crazy larry for the best fuel economy. But as ah64 mentioned the engine wiring harness is different, the injector wiring is hidden under valve cover. Fount out when i got home from the dealer and realized i couldnt use my edge juice module...

This pretty much sums it up. I would like to add: The 06 ecm is much more powerful allowing for integrated exhaust brake control and a few other minor options without pushing the limits of the computers memory. The head was modified for better flow along with a slight change in valve seat composition and increased exhaust valve lash.

CHECK to see if the wiring hook up is the same and see if the brain box is the same!