Bought the truck new in June 2005 and just turned 150k. Truck has been very reliable but has had a few hiccups. Used for towing a 275 Arctic Fox fifth wheel, 13000 gross weight, although I weighed it fully loaded and it was 11,700. Biggest problem ever encountered was the intercooler had plastic caps, let go in Kansas at about 110K, resulting in being towed 90 miles to a dealer in Wichita for repairs. Never towed other than that. Installed a Pac Brake exhaust brake at 30k and love it.I had a few issues with the brake but Pac Brake customer service went above and beyond. Finally changed brakes at 115k and that was only because rear wheel seal leaked and contaminated the emergency brake shoes and the brake pads. All maintenance was performed by myself except the intercooler. Just did the 150k valve adjustment so I am ready to leave on a 6k trip next Thurs.

Nice report. Yup, the 05 was known for the intercooler issue. Lucky you made it that long.

I'm surprised you still have all original injectors, but good report with very little miles for a 05. These are the type of trucks we like to purchase for our farm and ranch use.I'm knocking 150k miles on my '12 truck.

My 2006 with 193,000 has all original engine parts. A few rear u-joints and an AC compressor are the only repairs. One set of rotors and two sets of brake pads. BDExaust brake is easily the best addition. Really saves brakes.. I tow a 7000 pound toy hauler and a 10,000 pound enclosed car trailer. Both bumper pull.

Guess you guys got lucky. At almost 100,000 miles on my 2002 Cummins with 6 speed manual and Arctic Fox TC I've had:Failed PacBrake compressor$3000 worth of front end workA complete failure of the ECM main computer ($2000 more)Air conditioning water leaking into passenger side floorOil leak near the top rear of the engine that was inaccessible. BIG 3 Diesel in Tampa misdiagnosed it as a main seal, charged me around $3000, put new clutch plates in and put something together wrong and now the truck won't shift until the transmission is hot from highway use. It grinds BAD when cold since they broke all of that and they have no idea what they did wrong. Definitely don't go there. In addition, at 10 miles a gallon, this junker is very expensive to run

I did replace the exhaust manifold due to excess expansion, pretty common I understand, caused it to whistle when exh brake was applied. Pac Brake replaced the CHINEESE compressor with one built in Canada, been great since. Never could understand why they would build a quality exhaust brake and use a junk Chineese compressor.

150,000 mile Report on my 2005 Cummins | Good Sam Community

SweetLou
Explorer
May 18, 2018
Cummins12V98 wrote:
SweetLou wrote:
HadEnough wrote:
Guess you guys got lucky.

At almost 100,000 miles on my 2002 Cummins with 6 speed manual and Arctic Fox TC I've had:

Failed PacBrake compressor
$3000 worth of front end work
A complete failure of the ECM main computer ($2000 more)
Air conditioning water leaking into passenger side floor
Oil leak near the top rear of the engine that was inaccessible. BIG 3 Diesel in Tampa misdiagnosed it as a main seal, charged me around $3000, put new clutch plates in and put something together wrong and now the truck won't shift until the transmission is hot from highway use. It grinds BAD when cold since they broke all of that and they have no idea what they did wrong. Definitely don't go there.
In addition, at 10 miles a gallon, this junker is very expensive to run

That G56 is a bad natch up if you tow heavy. The dual mass fly wheel won't hold up. I know because my previous 05 had it and I'm happy its gone

South Bend clutch can take care of that! That gen 6 speed is much tougher than the current one.

When you are paying 60-80 K for a new truck, they should put a special note saying something like "South Bend Clutch can take away the unreliability of your clutch after it ***** out. BTW, it will be noisy after you do it". That should sell more of them
sidewayzz
Explorer
May 17, 2018
192000. water pump at 125000. normal maintenance every 5000 to 6000 miles. 15w 40 premium blue. trans serviced every 30000. I have followed the original owners service schedule. I will use stanadyne fuel additive every once in awhile.
Grit_dog
Navigator
May 17, 2018
transamz9 wrote:
I believe I would check into a different mechanic. 2002 with 100k miles more than likely just had a corroded pin or two causing the ECM to appear be bad. I've fixed two of them by simply unplugging, spraying and plugging back in. Condensation coming in the cab is cause by debris getting in the cowl. Seals drying out and leaking will happen on any of them that sit as much as that 2002.

Yeah Hadenough has just had enough of a schitty mechanic. ECM aside, the rest of it is misdiagnosed or poor repairs, or possibly not needed at all. But that's Dodges fault.....
And fish, you got the G56 clutches confused with HEs truck. The NV 5600 OE clutch is solid and his mechanic apparently s ucks. And a new ECM is $300-700 plus a little diagnose and replace time. 2 grand is just another ripoff. As well, not a common issue.
transamz9
Explorer
May 16, 2018
I believe I would check into a different mechanic. 2002 with 100k miles more than likely just had a corroded pin or two causing the ECM to appear be bad. I've fixed two of them by simply unplugging, spraying and plugging back in. Condensation coming in the cab is cause by debris getting in the cowl. Seals drying out and leaking will happen on any of them that sit as much as that 2002.
HadEnough
Explorer
May 16, 2018
FishOnOne wrote:
rhagfo wrote:
HadEnough wrote:
Guess you guys got lucky.

At almost 100,000 miles on my 2002 Cummins with 6 speed manual and Arctic Fox TC I've had:

Failed PacBrake compressor
$3000 worth of front end work
A complete failure of the ECM main computer ($2000 more)
Air conditioning water leaking into passenger side floor
Oil leak near the top rear of the engine that was inaccessible. BIG 3 Diesel in Tampa misdiagnosed it as a main seal, charged me around $3000, put new clutch plates in and put something together wrong and now the truck won't shift until the transmission is hot from highway use. It grinds BAD when cold since they broke all of that and they have no idea what they did wrong. Definitely don't go there.
In addition, at 10 miles a gallon, this junker is very expensive to run

I would say the other way around, you are either unlucky, or don't take care of your truck!

Our 2001, bought used at 234K, now has 307K and nary an engine issue. Yes needed front end work, and after a small chip needed a stronger clutch, but just normal maintenance above that.

How can you abuse a ECM, cause an oil leak, cause condensation draining into the cab? The clutches are absolute junk!

Right??? I was trying to not get into an argument with the guy but what preventative maintenance do I need to be doing on my ECM? Lol
Maybe I should have pulled apart the engine and replaced the gasket as preventative maintenance before the oil leaked?
Granted, maybe I should have inspected the air-conditioner plumbing for faulty connections but that's a big stretch too.
FishOnOne
Nomad
May 16, 2018
rhagfo wrote:
HadEnough wrote:
Guess you guys got lucky.

At almost 100,000 miles on my 2002 Cummins with 6 speed manual and Arctic Fox TC I've had:

Failed PacBrake compressor
$3000 worth of front end work
A complete failure of the ECM main computer ($2000 more)
Air conditioning water leaking into passenger side floor
Oil leak near the top rear of the engine that was inaccessible. BIG 3 Diesel in Tampa misdiagnosed it as a main seal, charged me around $3000, put new clutch plates in and put something together wrong and now the truck won't shift until the transmission is hot from highway use. It grinds BAD when cold since they broke all of that and they have no idea what they did wrong. Definitely don't go there.
In addition, at 10 miles a gallon, this junker is very expensive to run

I would say the other way around, you are either unlucky, or don't take care of your truck!

Our 2001, bought used at 234K, now has 307K and nary an engine issue. Yes needed front end work, and after a small chip needed a stronger clutch, but just normal maintenance above that.

How can you abuse a ECM, cause an oil leak, cause condensation draining into the cab? The clutches are absolute junk!
Shovelhead_Dave
Explorer
May 16, 2018
Getting ready to head West tomorrow and my talk of how good the truck has been bit me, the exhaust broke at the muffler outlet. Thirteen years...just can't get anything to last.
Gulfcoast
Explorer
May 16, 2018
jmtandem wrote:
He was emphatic that Cummins was of the opinion that no fuel additives were needed so I listened, haven't used any yet.

Cummins recently changed their minds on additives to the fuel. They now endorse additives. Folks in our area are getting as much as 500,000 out of injectors using additives. Not sure where the very low 150,000 mile numbers are coming from; maybe folks that buy the cheapest fuel possible, poor fuel filter maintenance, etc.

What additives are you using to get the high mileage on the injectors?
rhagfo
Explorer III
May 16, 2018
HadEnough wrote:
Guess you guys got lucky.

At almost 100,000 miles on my 2002 Cummins with 6 speed manual and Arctic Fox TC I've had:

Failed PacBrake compressor
$3000 worth of front end work
A complete failure of the ECM main computer ($2000 more)
Air conditioning water leaking into passenger side floor
Oil leak near the top rear of the engine that was inaccessible. BIG 3 Diesel in Tampa misdiagnosed it as a main seal, charged me around $3000, put new clutch plates in and put something together wrong and now the truck won't shift until the transmission is hot from highway use. It grinds BAD when cold since they broke all of that and they have no idea what they did wrong. Definitely don't go there.
In addition, at 10 miles a gallon, this junker is very expensive to run

I would say the other way around, you are either unlucky, or don't take care of your truck!

Our 2001, bought used at 234K, now has 307K and nary an engine issue. Yes needed front end work, and after a small chip needed a stronger clutch, but just normal maintenance above that.
Shovelhead_Dave
Explorer
May 16, 2018
ShinerBock
He worked there from 1999 to 2009, first in Indiana then South Carolina on Boat retrofits. Went back to Boeing after the 2008 crash.