This page is dedicated to OEM-fit replacements for daily drivers, tow rigs, and restorations. If you’re seeking larger-frame performance turbos, compounds, or T4 conversions, see the related links at the bottom. Product pages list year-specific notes, included hardware, and installation guidance.
What’s covered (5.9L Cummins model years)
- 1989–1993 (12-valve, 1st Gen): Direct-fit manifold and turbo replacements for reliable cold starts, steady boost, and stock towing manners.
- 1994–1998 (12-valve, 2nd Gen): OEM-equivalent hot-side components that help maintain EGT control and sealing under repeated heat cycles.
- 1998.5–2002 (24-valve): Stock-fit manifolds/turbos with correct flange geometry, actuator and sensor compatibility for factory behavior.
- 2003–2007 (Common-Rail): Replacement units that preserve OE spool, emissions compatibility, and service access in the 3rd-gen engine bay.
Why choose DPS stock-replacement parts
- True OEM fitment: Correct flange patterns, wastegate/actuator locations, and porting for MAP/EGT/drive-pressure (where applicable).
- Built to last: High-nickel, thick-wall castings and flat-machined flanges resist warping, cracking, and leaks.
- Stable EGT & drivability: Clean internal flow supports consistent boost control and factory torque delivery under load.
- Emissions-system friendly: Designed to work with stock aftertreatment when installed as directed.
- Fleet & daily-use ready: Reduced downtime with repeatable installs and dependable sealing.
How to pick the right 5.9 replacement
- Match your OE part: Confirm model year, turbo/manifold flange, actuator style, and sensor/port requirements.
- Check surrounding hardware: Plan fresh gaskets, studs/nuts, crush washers (if equipped), and heat shields.
- Usage profile: For stock power and towing, choose like-for-like. If planning future horsepower increases, consider our performance categories instead of OEM-fit replacements.
Fitment checklist
- Verify T3 vs T4/T4i flange and downpipe connection for your year.
- Confirm wastegate/actuator type and sensor provisions (MAP/EGT/drive-pressure if used).
- Inspect cylinder-head and turbo mating faces; correct any warpage or carbon tracking before install.
Install & first-drive tips
- Use new gaskets and quality hardware; torque in sequence on a cold engine.
- Pressure-test charge-air and pre-turbine joints before first start to catch leaks.
- Re-check fastener torque after initial heat cycles where the service manual specifies.
Related categories: All OEM-Fit Replacement Parts · Dodge Cummins Platform Hub
Building beyond stock? Explore performance (not OEM-fit): 5.9 Cummins Performance Manifolds or S300 Single Turbos.
Frequently asked questions
Do I need tuning for a stock-replacement turbo or manifold
No. Like-for-like replacements are designed to run on factory calibration. If turbo size or fueling changes, tuning may help drivability and EGT control.
Will these parts work with emissions equipment
Yes. These are OEM-fit components intended to operate with factory systems when installed as directed. Always follow local regulations.
How do I confirm the correct part for my 5.9
Match year/engine family, flange type, actuator style, and sensor/porting. If unsure, contact us with VIN and existing part numbers.
What symptoms suggest my turbo or manifold needs replacement
Persistent exhaust leaks, soot tracking, boost loss, slow spool, excessive shaft play, whistle/grind noises, or repeated EGT spikes under normal load.
Are DPS replacements stronger than OEM
Our thick-wall castings and precision machining are engineered for durability and sealing through repeated heat cycles, meeting or exceeding OE performance in stock applications.
