FrankBUILT Performance 2003-2007 Cummins 5.9L 24V Head Gasket Kit w/Studs

Head Set Kit w/ Fastener, Gasket & Cylinder Head Options – 2003–2007 Dodge Ram 5.9L Cummins (Common Rail)

Rebuild your top end with confidence. This kit is built around the MAHLE Head Set HS54557, a quality-tested, direct-fit replacement that includes a multi-layer steel (MLS) head gasket and the upper-engine gaskets/seals you need to button up the job right.

What’s Included (Base – MAHLE HS54557)

• MLS Head Gasket: 1.28 mm thickness, 102.0 mm standard bore
• Complete top-end gasket set: intake & exhaust manifold gaskets, valve cover gaskets/seals, injector & crossover sealing washers, thermostat housing, and assorted upper-engine O-rings/seals (contents may vary slightly by model year)
• Note: Cylinder head bolts are not included in the base set—choose your required fastener option below.

Head Fasteners (Required)

Choose one: OEM-style head bolts (budget refresh) or performance head studs (higher, more consistent clamping—recommended for tuned/boosted setups).

• Mahle GS33493 — OEM-style head bolt set (+$163.61)
• Cummins 3927063 — Genuine Cummins head bolt set (+$227.50)
• ARP 247-4202 — Performance head stud kit (ARP 2000-type alloy) (+$473.13)
  Great for stock to moderately tuned trucks; reusable with correct procedure.
• ARP 247-4204 Custom Age 625+ — Premium head stud kit (+$1,232.29)
  Maximum strength for high boost/competition builds.
• PPE 218034300 — head stud kit (+$413.99)
• PPE 218034350 High Yield — high-yield head stud kit (+$1,214.99)

Head Gasket Upgrade – Optional (Limited Inventory)

Step up from the included MLS (1.28 mm, 102 mm bore) if your machine work or goals call for it.

• No — Keep included MLS (HS54557)
• Cummins 3958645 (Thick) (+$316.95)
  Choose when decked surfaces or piston protrusion measurements indicate the need for a thicker compressed gasket to maintain quench/compression.
• Cummins 3958644 (Thin) (+$275.49)
  Choose when minimal material has been removed and protrusion is on the low end of spec.

Cylinder Head Options – Optional

Add a ready-to-install cylinder head to streamline your refresh. Some selections require a refundable core deposit; choose “Send Core First” to avoid an upfront core charge.

• Power Driven Stock 5.9L/6.7L Cummins Cylinder Head (24v CR) (+$1,730.78)
• Power Driven Stage 1 Towing Performance CNC-Ported Head (’03–’18 5.9L/6.7L CR) (+$2,407.50)
  Optimized for towing/low-mid RPM torque and EGT control.
• Power Driven Stage 2 Hot Street CNC-Ported Head (’03–’18 5.9L/6.7L CR) (+$3,172.50)
  Higher airflow for aggressive street/strip builds.
• Power Driven CNC Ported Induction Street Series Head (5.9L/6.7L) (+$2,767.50)
  Balanced street performance with improved port efficiency.
• Fleece 61-10005-HD Freedom Street HD Series Head (’03–’07 5.9L) — Send Core First (+$2,599.00) or Pay Core Upfront $500 (+$3,099.00)
  HD street replacement with durability upgrades.
• Fleece 61-10006 Freedom Performance Series Head (’03–’07 5.9L) — Send Core First (+$3,750.00) or Pay Core Upfront $700 (+$4,450.00)
  Performance-oriented head for higher airflow demands.
• D&J Precision Machine Remanufactured Cylinder Head — Send Core First (+$2,204.99) or Pay Core Upfront $800 (+$3,004.99)

How Core Handling Works

• Send Core First: Ship us your core; we ship your head once the core is received and inspected (no core charge on the order).
• Pay Core Upfront: A refundable core charge is included in the price. We refund after your core passes inspection.

Fitment

• 2003–2007 Dodge Ram 2500/3500 — 5.9L Cummins (24-Valve Common Rail)

Technical Notes

• Surface prep matters: verify head/block flatness and surface finish (RA) for MLS gaskets.
• Torque & sequence: follow the fastener manufacturer’s lube and torque specs; values differ by material and lubricant.
• Gasket thickness: select based on measured piston protrusion and any machine work; when in doubt, ask—we’ll spec it.

Questions? Not sure which fasteners, gasket thickness, or head is right for your build? Tell us your power goals and use case and we’ll dial in the combo.