cummins 5.9 fuel line leaks
 

I have a 2005 2500 dodge diesel. For the second time it has developed a fatigue crack in a hard line from the fuel rail to the injector. This one was on #4. The line is about 7" long ($86) with a clamp in the middle. Not sure which one it was the first time because it quit in the middle of traffic and had to be towed and fixed under warranty.
I have looked on the internet and have found this is a common problem. They crack right behind the end of the ferrel at the injector end. Enough that some guys are keeping an extra one in the truck and the 2 wrenches to change it.
Anyone seen this problem and or know of a solution?

Re: cummins 5.9 fuel line leaks
 

Tighten the new one carefully so the support/vibration bracket has no stress on the line. #6 occasionally cracked until a support bracket was added around 2005 or so; it goes to the engine lift bracket bolt that is converted to a bolt/stud. #4 is the most common one to fail for some reason. Get it from Cummins for about $25-30.

Re: cummins 5.9 fuel line leaks
 

I have an '05 2500 w/ Cummins 5.9. I have all of 44,000 miles on it, mostly towing, should I be worried? I've never heard of this! Jim

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Re: cummins 5.9 fuel line leaks
 

I worry a lot about a lot of things so I carry spare lines and a 3/4" open end wrench. I wouldn't say the failure is common but it happens enough to be cautious, especially if you go on long trips, etc. You can't just continue running with a cracked line as it is under rail pressure all the time. Rail pressure does go up with more accelerator pedal, from about 5000 psi at idle to a max of about 23,000 psi.

Re: cummins 5.9 fuel line leaks
 

Here ya go:

http://www.dieselbombers.com/5-9-lit...ctor-line.html


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Re: cummins 5.9 fuel line leaks
 

what years are affected??? are any immune or is it a problem that any 5.9 cummins might have??? my son has a 2008

Re: cummins 5.9 fuel line leaks
 

Hi All,

Tese are a great resource for information on all Dodge Diesels.....

http://www.dieseltruckresource.com/dev/index.php

http://www.cumminsforum.com/forum/

Bob

Re: cummins 5.9 fuel line leaks
 

The original club and its website are still very good:
www.turbodieselregister.com

Re: cummins 5.9 fuel line leaks
 

I used the TDR forum for years and when they started to charge $35.00 a year to subscribe, I found my information at the free sites.

Bob

Re: cummins 5.9 fuel line leaks
 

I haven't heard of any issues with the 6.7, and thankfully I've only had 1 injector fail on my 06 5.9, which filled the engine with diesel :eek:.

Clark