How to: 5.9 Cummins head gasket replacement (part 1/2 Removal)

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This is a step by step video for replacing the head gasket on a 5.9 cummins. This is the first of two videos, this video covers the removal procedure. The truck in the video is a 2003 ram 2500 5.9 but the procedure should be pretty much the same for any 5.9 common rail cummins.
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Fast Forward Times:
Intro 0:00
Rocker arms, bridges and pushrods 4:28
Injector fuel lines 7:30
Fuel injectors & fuel tubes 8:02
Fuel rail 9:59
Alternator 12:30
Exhaust manifold 13:14
Head bolts 15:45
Cylinder head 17:08
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6 авг 2024

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Комментарии : 75

@sicsempertyrannis8830 4 года назад

Pro tip. Cut the fingers off some rubber gloves and rubber band them to all exposed fuel lines and plastic bag injector and tubes if you plan to re-use them. If Small bits of crud and shop dust make there way into the injectors you may end up buying new injectors worce case injector hangs open and your then you got even bigger problem. This is unlikely but has happened so keep everything as clean as possible.

@ericbickell4 10 месяцев назад

I'm just mechanical enough to get myself in trouble but I can follow instructions. Both this video and the part 2 install were great. Saved me thousands of dollars paying someone to do the work for me. Thanks

@darkirondiesel 10 месяцев назад

These are my favourite comments to get. Glad I could help!

@jpag8764 3 года назад

I just added a Banks exhaust brake on my 06 and it came with a new coolant crossover tube. That tube is fastened to a stud on the drivers side on top of transmission bell housing. It ties into the torque converter cooler. You cannot remove the tube unless you remove it from that stud (10mm nut). Sorry I'm 5 months late but it took me 3 frustrating days just trying to remove that tube. Just had to walk away and regroup

@jimeylee2036 2 года назад

Thanks for the video. Saved me a lot of stress. I’m not afraid to try my own repairs no matter how involved. Videos like yours make it way better! I had blow by issues and your video was one of the best for hitting all steps! Turns out I had problems with 3 and 6 and a light groove on the cylinder wall. On the heater hose bracket on the passenger side….I just bent mine and it came off. Had to straighten it after putting it back. Cut it? Bend it…? Same story. Thanks again for the video!

@TejasCummins 4 года назад

Perfect timing for this video, I’m doing a head gasket this weekend.

@darkirondiesel 4 года назад

Good luck buddy!

@russellkeast8993 4 года назад

Canadian channel all the way! Keep up the good diesel content man!

@MikeHoncho5486 8 месяцев назад

Watched this video 100 times. Thanks man

@dodger98 3 года назад

Where you asked about the coolant line bracket on number 6 rear exhaust manifold bolt, if you go on the drivers side there’s another bracket with a 10mm bolt you take that out and the whole thing slides off. Can reach it from underneath behind the drivers side tire

@darkirondiesel 3 года назад

Thanks!

@dodger98 3 года назад

@@darkirondiesel no problem, keep up the good work!

@johnjohn-pu1im 2 года назад

15:00 :)

@freerepublicusa2064 3 года назад

Great content. Greetings from Las Vegas NV.

@allenkeith1846 3 года назад

Good looking truck man ,like the color

@nathancasey1806 3 года назад

HELPED ALOT THANK YOU

@selectyourtools 3 года назад

Good video man!

@jackkessler7870 3 года назад

Good video, thanks for sharing

@HelloKittyFanMan. 3 года назад

Why do you have to remove the injectors and tubes in order to lift the head, if all that stuff is just in the head and not the block, and those things aren't really long like the pushrods?

@jamesvuxta8723 2 года назад

Thanks for sharing someday I might need to do the same

@terrellscaife2411 2 года назад

Nice work homie

@sempergumby8734 Год назад

Very helpful 👍

@jsmedbond 3 года назад

Wow! Great vid with excellent detail. Way too much pain in the arse work for me. I'm going to just pay a diesel shop to do it. ;-)

@edrianthrodriguez6763 9 месяцев назад

Thanks for the video 🤙

@garytimmons7015 Год назад

Very good video thank you

@ChikzDigit 3 года назад

I am going to be pulling the head off my 2005 here soon, will be using this video for reference.... Thanks I have real bad blow-by, oil all over the underside of my truck, tailgate, and side of trailer!!!! Ugh

@YOUTHOUGHT2 3 года назад

Out of curiosity, have you checked your dipstick tube? Mine was cracked about half way down and was sending oil everywhere not to mention the leak coming from the range sensor on the side of the trans made it a real mess. These trucks can have minimal blow by but look at a few other things unless your cap is flying off while it’s idling. Mine kinda just stumbles but moves from the fan lol

@ChikzDigit 3 года назад

@@YOUTHOUGHT2 yep, not it

@EddieLife3500 2 года назад

Awesome video

@darkirondiesel 2 года назад

Thanks buddy I appreciate it!

@RobertKohut 3 года назад

Nice!!

@drewgerber3525 3 года назад

This is a Great Video Kyle, I have watched it twice now. Where do you drain the diesel fuel at so you don't have diesel fuel running all over the place when you disconnect the fuel lines. I am doing a full motor swap and rebuilding the motor I am taking out for another project. But this video was great for removing the head.

@darkirondiesel 3 года назад

Thanks! I don’t really drain the fuel myself, usually when you remove the fuel lines only a few drops of diesel come out. You could drain it at the fuel filter, and maybe at the cp3 pump, but I don’t know if there is a way to get zero spillage.

@HelloKittyFanMan. 3 года назад

I haven't been able to loosen any of the exhaust manifold bolts that hold it to the turbo, and I can't loosen the turbo bolts either. But I have unbolted the manifold from the head, so I should be able to pull the head up and away from the manifold anyway, right?

@HardiganFarms 7 месяцев назад

Where was your injectior pump and cable removal?

@oksanatuszynski8042 Год назад

Hi I bought a 5.9 03 with 81miles. My first diesel. I know nothing about them. However something just dies not sit right woth me it has a funny noise starting up when cold. It's like a knock. I was told at one point water pomp did blew up they replaced it. Where do I start. WI figuring out wjst to replace or whst test to do at the shop. Thank you. BTW. Blow by test was fine

@BrodyRuoff-zg7qr 3 месяца назад

How long did the head gaskets whole process end up taking?

@Allmotorzl1 3 года назад

Could you replace pistons, rod and main bearings while the engine is in the truck?

@darkirondiesel 3 года назад

I’m not 100% sure... I think you can, but honestly for the extra time it would take to pull the engine right out you would probably save that in struggling with the engine in frame.

@Allmotorzl1 3 года назад

@@darkirondiesel You are probably right. Time to make a cummins removal vid lol. Thanks

@willardcornelius9635 2 года назад

Looking for head bolts or a.r.p head studs

@rafaelsandoval3867 2 года назад

I have a question, how much does it cost for that job?

@bgt63 2 года назад

If there is a crack...is it usually the head? I had one shop tell me they recommend just order a new head for every job because theybare usually cracked or warped

@darkirondiesel 2 года назад

Ya usually but that’s rare. Cummins have steel heads and they don’t tend to crack very often. That’s why you take the head to get decked and pressure tested. They will find cracks if there are any.

@bgt63 2 года назад

@@darkirondiesel finding out today....i am deep in prayer. Lol

@DPats1228 3 года назад

We’re there any other symptoms besides pressurizing?

@naplestan 2 года назад

Depending on where the head gasket blows you could have white coolant steam as it dribbles onto the exhaust manifold.

@HelloKittyFanMan. 3 года назад

Why is there a fuel line on the back of the head?

@stevewinwood3674 5 месяцев назад

11:16 what is that rear fuel line for?

@joseaguinaga7670 3 года назад

how many hours total do you estimate for a head gasket replacement?

@darkirondiesel 3 года назад

@petersannicolas8949 4 года назад

How many miles would you recommend to do a new head gasket replacement?

@darkirondiesel 4 года назад

I’d only replace it if it needed to be replaced. Some trucks seem to go forever without having a failed head gasket and some trucks don’t. Driving your truck nice and not on a stupid high horse power tune will help the life of your gasket.

@petersannicolas8949 4 года назад

10-4

@petersannicolas8949 4 года назад

How much would it be to replace a headgasket on a 05 5.9l cummins common rail roughly

@bgt63 2 года назад

@@petersannicolas8949 Calgary Canada 2004 5.9 quoted 5000.CDN at a reputable shop....i should throw the truck away but im stubborn

@deakongolla3838 4 года назад

How good are the Cooper tires u got?

@darkirondiesel 4 года назад

I have no complaints other then they are expensive. I bought them used from a friend when he went from the 37s to a 38” tire so I got them for a good price

@deakongolla3838 4 года назад

@@darkirondiesel how noisy do they get(road noise don't bother me). And how good are they in snow.

@coopersmith9748 7 месяцев назад

How necessary is it to deck the head?

@darkirondiesel 7 месяцев назад

I’m not sure, I was always taught to deck the head so I’ve always done it. If you’re looking to be quicker or cheaper you could clean it up yourself with a light buffer disk but do it at your own risk.

@joseaguinaga7670 3 года назад

Why is it important to put the tubes and bridges in order to put them back in the same cylinder number? I have done many injectors on my truck ( 5.9 cummins)usually 3 at a time and i have mixed them up , and no problems once I finish . no issues whatsoever. truck has 346 ,000 miles already.

@darkirondiesel 3 года назад

Because of wear patterns. I’m sure you could mix up parts and be fine but if you want PROPER technique you gotta put everything back where it came from. The injector fuel tubes are extremely important that they go back with the same injector because they are a crush fit, so when you torque them the metal actually crushes into the injector and that’s what creates the seal. You are actually supposed to change those fuel tubes every time you remove one, but personally I only put new ones in whenever I put new injectors in, but I ALWAYS match them up to the same injector they were with originally because of that crush fit. So if you mixed yours up there’s a good chance you are leaking a little bit of fuel there, might not be enough to notice any difference but still you should always do things the proper way.

@mxerb5912 3 года назад

I found a decomposed rat on top of my steering box while removing it. Glad I saw the tail before it dropped on my face!

@darkirondiesel 3 года назад

That’s disgusting 🤢

@zackpeterson7538 4 года назад

Do you have to send it to the shop or can you just throw the new head gasket on and send it lol

@darkirondiesel 4 года назад

I’d strongly recommend getting it pressure tested and resurfaced. Would be a shame to do the whole job just to have it pressure up again and then find out your head was cracked or not cleaned properly.

@MikeMiller-nn1pj 4 года назад

Pitter patter let's get at er

@Todohongo 3 года назад

That coolant bracket on the back of the head is a pain in the ass. I was able to pry it back just enough to clear that stud and then take off one of the hose clamps near the front and I could get it out of the way and get a socket on that nut. Pain in the ass when you can’t see shit haha

@darkirondiesel 3 года назад

Haha ya man it’s brutal trying to work just by feel and no visual

@Todohongo 3 года назад

Good video man, thanks for the help and info by the way