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Comprehensive 2nd Gen 5.9L Cummins Maintenance Guide & Parts List

How to maintain your 2nd Generation Dodge Cummins Diesel Truck

If you’re reading this, you’re probably the proud owner of a 2nd Gen Cummins. The term second generation Cummins refers to 1994-2002 Dodge Ram pickup trucks equipped with either the 5.9L 12 valve Cummins engine, or the 5.9L 24 valve Cummins engine. These trucks had big shoes to fill because of how successful and durable the first generation Cummins was. Thankfully, despite becoming slightly more sophisticated, these trucks are also very reliable. Much of your truck’s reliability, however, is dependent on you being an expert on 2nd Gen Cummins Maintenance. If you’re not familiar with diesel trucks or a diesel mechanic, this can be a difficult task.

There’s no need to worry. This post is our comprehensive guide to 2nd Gen Cummins maintenance and it’ll give you everything you need to take care of your truck. We go over the correct service intervals to follow depending on how you use your truck. We will also make recommendations on the best filters, fluids, and motor oil to use and we even link to where you can buy them on Amazon! You’ll also learn how much of each fluid or oil is required, so you can purchase the right amount.

2nd Gen 5.9L Cummins Maintenance Guide
2nd Generation 5.9L Cummins

Don’t be a cheap/lazy A**

People often fall short because they don’t know what the proper second generation Cummins maintenance intervals are. Sometimes people know the intervals but they just want to extend them a little bit to save some dollars now. Just remember, neglecting your truck can lead to major, unnecessary repairs down the road. Another common shortfall is using cheaply made aftermarket filters and fluids. DON’T USE AFTERMARKET FILTERS OR FLUIDS. They’re not nearly the same quality as the OEM products they substitute for. Stick with Mopar or Fleetguard. Spend the money now to save yourself in the future. Now go out there and give ol’ Bessy the servicing she’s been needing.

Which Variation of the 2nd Gen Cummins Do You Have?

Before we go any further, it’s important to know exactly what Cummins engine your truck has. Its important to know if you have a 12 valve or a 24 valve engine. The 12 valve will have very similar maintenance intervals and use many of the same parts as the first gen Cummins. This engine is found on 1994-1998 2nd Generation Cummins pickups. Beginning with 1998.5 model years trucks, a 24 valve design is used. You will have slightly different service intervals and need different parts for 1998.5-2002 trucks. If you want to know more about the differences between the two designs, visit our 2nd Gen Cummins specifications resource. Now that we’ve got this figured out, let’s take a look at how often you need to service your truck.

How Often Do I Need to Service my 2nd Gen?

How often should you service your truck depends on how you operate it. Do you tow heavy? Do you tow frequently? Do you live in a big city, or idle for extended periods of time? If you answered yes, you need to follow a severe service schedule. If you use your truck as a daily driver, tow heavy infrequently, or only tow light loads, the normal operating conditions service schedule is what you should follow. Not every component of your 2nd Gen Cummins needs maintenance every mileage milestone. There are some things you’ll want to do every time you service your truck though. Check out the bullet points below.

9 Things You Should do Every Time You Perform Service

  • Inspect all steering and suspension components for wear
  • Thoroughly inspect exhaust system
  • Check all components holding oil or fluid for leaks.
  • Check your driveway or wherever your truck is normally parked for signs of any leaks
  • Inspect Brake hoses
  • Rotate your tires
  • Check all fluid levels
  • Check your tires for nails, screws, bulges, or other damage.
  • Drain water from fuel filter**** MONTHLY

12V 5.9L Cummins Service Intervals

Follow these service schedules if you have a 1994-1998 12 valve 2nd Generation Cummins.

Normal Operating Conditions

Maintenance/ServiceMilesKilometersMonths
Change Oil6,000 miles9,600 km6 mo.
Change Oil
Filter
6,000 miles9,600 km6 mo.
Replace Fuel
Filter
12,000 miles19,200 km12 mo.
Replace Engine Air
Filter
Check Every Service
interval, replace
as necessary.
See LeftSee Left
Flush Cooling
System (Initial flush)
36,000 miles57,600 km36 mo.
Flush Cooling
System (After Initial flush)
30,000 miles48,000 km24 mo.
Drain & Re-Fill
Automatic Transmission
Fluid
24,000 miles38,400 km24 mo.
Replace automatic
transmission Filter(s)
24,000 miles38,400 km24 mo.
Adjust Automatic
Transmission Band
24,000 miles38,400 km24 mo.
Flush & Re-fill
Manual Transmission
Fluid
60,000 miles96,000 km36 mo.
Replace Transfer
Case Fluid
36,000 miles57,600 km36 mo.
Adjust Valve
Lash
24,000 miles38,400 km24 mo.
Replace Rear
Differential Fluid
Not Specified by FCA,
at least once every
100,000 miles or
5 years
See LeftSee Left
Replace Front
Differential Fluid
Not Specified by FCA,
at least once every
100,000 miles or
5 years
See LeftSee Left

Severe Operating Conditions

Maintenance/ServiceMilesKilometersMonths
Change Oil3,000 miles4,800 km3 mo.
Change Oil
Filter
3,000 miles4,800 km3 mo.
Replace Fuel
Filter
12,000 miles19,200 km12 mo.
Replace Engine Air
Filter
Check Every Service
interval, replace
as necessary.
See LeftSee Left
Flush Cooling
System (Initial flush)
36,000 miles57,600 km36 mo.
Flush Cooling
System (After Initial flush)
30,000 miles48,000 km24 mo.
Drain & Re-Fill
Automatic Transmission
Fluid
12,000 miles19,200 km12 mo.
Replace automatic
transmission Filter(s)
12,000 miles19,200 km12 mo.
Adjust Automatic
Transmission Band
12,000 miles19,200 km12 mo.
Flush & Re-fill
Manual Transmission
Fluid
60,000 miles96,000 km36 mo.
Replace Transfer
Case Fluid
36,000 miles57,600 km36 mo.
Adjust Valve
Lash
24,000 miles38,400 km24 mo.
Replace Rear
Differential Fluid
12,000 miles19,200 km12 mo.
Replace Front
Differential Fluid
12,000 miles19,200 km12 mo.

24V 5.9L Cummins Service Intervals

Follow these service schedules if you have a 1998.5-2002 24 valve 2nd Generation Cummins.

Normal Operating Conditions

Maintenance/ServiceMilesKilometersMonths
Change Oil7,500 miles12,000 km6 mo.
Change Oil
Filter
7,500 miles12,000 km6 mo.
Replace Fuel
Filter
15,000 miles24,000 km12 mo.
Replace Engine Air
Filter
Check Every Service
interval, replace
as necessary.
See LeftSee Left
Flush Cooling
System (Initial flush)
30,000 miles48,000 km24 mo.
Drain & Re-Fill 47RE
Automatic Transmission
Fluid
30,000 miles48,000 km24 mo.
Replace automatic
transmission Filter(s)
30,000 miles48,000 km24 mo.
Adjust Automatic
Transmission Band
30,000 miles48,000 km24 mo.
Flush & Re-fill
Manual Transmission
Fluid
60,000 miles96,000 km36 mo.
Replace Transfer
Case Fluid
90,000 miles144,00 km72 mo.
Replace Rear
Differential Fluid
Not Specified by FCA,
at least once every
100,000 miles or
5 years****
See LeftSee Left
Replace Front
Differential Fluid
Not Specified by FCA,
at least once every
100,000 miles or
5 years****
See LeftSee Left
Adjust Valve
Lash
150,000 miles241,000 kmN/A

Severe Operating Conditions

Maintenance/ServiceMilesKilometers
Change Oil3,750 miles6,000 km
Change Oil
Filter
3,750 miles6,000 km
Replace Fuel
Filter
15,000 miles24,000 km
Replace Engine Air
Filter
Check Every Service
interval, replace
as necessary.
See Left
Flush Cooling
System (Initial flush)
30,000 miles48,000 km
Drain & Re-Fill 47RE
Automatic Transmission
Fluid
15,000 miles24,000 km
Replace automatic
transmission Filter(s)
15,000 miles24,000 km
Adjust Automatic
Transmission Band
15,000 miles24,000 km
Flush & Re-fill
Manual Transmission
Fluid
60,000 miles96,000 km
Replace Transfer
Case Fluid
60-90,000 miles144-192,000 km
Replace Rear
Differential Fluid***
15,000 miles24,000 km
Replace Front
Differential Fluid***
15,000 miles24,000 km
Adjust Valve
Lash
150,000 miles241,000 km

**** If Front or Rear Axle submerged in water, fluid should be changed as soon as possible.

2nd Gen 5.9L Cummins Fluid Capacity

Oil/FluidCapacity – QuartsCapacity – Liters
Engine Oil /w Filter12 Quarts11.4 Liters
Auto Transmission Fluid
47 RE/RH
See Below
4 Quarts Service Refill
14.5-16.5 Quarts dry refill
See Below
3.8 Liters
8.2-15.6 Liters
Manual Transmission Fluid
NV4500
NV5600
See Below
4 Quarts
4.75 Quarts
See Below
3.8 Liters
4.5 Liters
Transfer Case
NP205
NP231
NP231HD
NP241
NP241HD
See Below
2.22 Quarts
1.25 Quarts
1.25 Quarts
2.4 Quarts
3.25 Quarts
See Below
2.1 Liters
1.2 Liters
1.2 Liters
2.2 Liters
3.1 Liters
Coolant24-26 Quarts22.7-24.5 Liters
Front Differential Fluid
Dana 60
See Below
3.15 Quarts
See Below
3 Liters
Rear Differential Fluid
2WD Dana 70
4WD Dana 70
2WD Dana 80
4WD Dana 80
See Below
3.5 Quarts
3.9 Quarts
3.4 Quarts
5 Quarts
See Below
3.3 Liters
3.6 Liters
3.2 Liters
4.8 Liters

2nd Gen Cummins Maintenance Parts – Fluids, Oil, Filters & More

The following chart is a collection of the parts you will need for 2nd Gen 5.9L Cummins Maintenance. When it comes to filters, you’re going to want to stick with Fleetguard or Mopar products. Aftermarket filters don’t offer the same filtration characteristics and because of their lesser quality, they can lead to premature part failures. You should also use Mopar fluids exclusively, except for engine oil. There are some really great 15W-40 Diesel engine oils for the 12V and 24V 5.9L Cummins engines. Shell Rotella products are excellent and i’ve used them in several of my Cummins-equipped Dodge Ram trucks.

Second Gen Cummins Maintenance Parts List

Part TypePart #Amazon Link
Engine Oil15W40Shell Rotella T4 15W40
Shell Rotella T5 (blend ) 15W40
Shell Rotella T6 15W40
Engine Oil FilterLF16035
LF3972
Fleetguard Stratopore LF16035
Fleetguard LF3972
Fuel Filter
’94-’96
’97-’99
’00-’02
See Below
FS1253
FS19598
FS19855
See Below
Fleetguard FS1253
Fleetguard FS19598
Fleetguard FS19855
Engine Air Filter25441
4189
(original) Fleetguard AF-25441
(superseded) Fleetguard AF-4189
Coolant
’94-’98 12V
‘98.4-’02 24V
N/A
N/A
Mopar
68048953AB
See Below
– 50/50 Mixture of Distilled
Water & glycol ethylene coolant
– 50/50 Mixture of Mopar
Antifreeze
& Distilled Water
Automatic
Transmission Fluid
for 47RE/RH
ATF+4Mopar ATF+4
Transmission Filters
’94-’97
’98-’02
See Below
3515996
52118789
See Below
Mopar 3515996
Mopar 52118789
Manual
Transmission Fluid
NV4500HD (5-Speed)
NV5600 (6-Speed)
See Options
Below
– SAE 75W-90
– Mopar MTF
See Options
Below
SAE 75W-90
Mopar Manual Trans. Fluid
Serpentine Belts
’94-’02
’94-’02 /w AC
’94-’02 No AC
See Below
53040171AD
K080810HD
K080653
See Below
Mopar 53040171AD
Gates K080810HD
Gates K080653
Upper Radiator Hose
’94-’98
‘98.5-’02
See Below
22081
22645
See Below
Gates 22081
Gates 22645
Lower Radiator Hose22082Gates 22082
Transfer Case FluidATF4+Mopar ATF+4
Front differential fluid
Dana 60
9.25″ AAM
See Below
SAE 75W-140
SAE 75W-90
See Below
SAE 75W-140 Synthetic Gear Oil
SAE 75W-90
Rear Differential Fluid
Dana 70
Dana 80
10.5″ AAM
11.5″ AAM
See Below
SAE 75W-140
SAE 75W-140
See Right
See Right
See Below
SAE 75W-140 Synthetic Gear Oil
SAE 75W-140 Synthetic Gear Oil
SAE 75W-90 or SAE 75W-140
SAE 75W-90 or SAE 75W-140

Learn More About the 2nd Gen Dodge Cummins

Want to learn more about the second generation 5.9L Cummins? Visit our other resources by clicking on one of the links below.

DISCLAIMER: This website page contains affiliate links, which means that if you click on one of the product links and purchase the product, I’ll receive a small commission. This helps support Diesel Resource and allows us to continue to produce helpful diesel insight and content. Thank you for the support!

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ABOUT Kamil

Founder of Diesel Resource and a complete diesel head. Has a little bit of problem buying too many trucks. Learn more about him by checking out his truck.