I have had a 97'12v in the past with the screws put to it~fun truck. I have been gone for a bit, driving an 05' Stroke, I did what it needed to be safe and reliable and built a little more power. I was happy with everything but the MPG on the stroke.
Anyway I'm looking to get back to a Cummins. It appears my budget and preferences put me in the 03'-07' range. I'm looking for reliability and maybe a little more power down the road. So I am looking for hints and tips regarding items to visually and seat of the pants to look out for on these trucks with the 5.9 24v. I have plenty of mechanical experience and understand most of the issues, I’m just not familiar with this vintage of Cummins.Besides there is a wealth of information right here with you guys

 

There's been a lot of posts about 5.9 CRs lately in the 3rd gen 2003+ section. You'll probably see everything you need in just the last 2-3 weeks. I went from a modded 97 215 to my 03 and it took a long time and many mods to be happy with the 03. Craig

 

where did ya move your batteries to?

 

Outside frame rails, behind the cab, to lighten the front end a little, make room for other things and get them away from the engine heat. Craig

 

I've had zero issues with the Cummins itself and have 135K miles on it, but the rest of the truck is another story, A/C compressor, accumulator, leaking rear window, driver's seat mounting bracket, recirc door and ball joints come to mind.

 

ok

if its a 4x4, obviously the front end, these motors will kill crappy front end components quick, and will have lots of slop in the steering wheel

secondy, motorwise, in a perfect world, the one you look at will have a 2 micron filtration system, chances are it does not, which will in turn lead to injectors, when where they done? stockers? factory filtration is not gonna cut it, and a bad tank of fuel can kill your injectors... truck is not making oil when you check the oil is it? no milky texture to the oil? if you have either or, it could be a bad injector, milky texture is coolant in the oil... oh and dont ignore the white smoke at startup if you see any..

thirdly, blowby, any in access? if you can take off the oil cap, put it on the filler neck, (right side up) and it blows off.. TURN AROUND AND RUN!

forthly, owner history, any programmer? ecm issues? dtc codes?

fifth, gooseneck hitch? any sign of heavy towing?

weak links on the CR cummins IMHO are the above stated... My truck has 220K miles on it and as major major repairs have only had injectors at 200K, and front end twice on it...

i do have a two micron filtration system, and i do use the truck for work, and check all fluids regularly

Finally having said that, and having a second and third gen?

the third gen is a FARRR nicer truck, but the second gen is more reliable...

my overall preferance? work the CR and enjoy the 12v.