5.9L Short Block Workhorse 2003-2004 – Cummins Dodge Diesel Engine

CHOATE-5.9L Cummins Workhorse Short Block Engine

2003-2004 – Dodge Cummins Diesel Engine Manufacturer: CHOATE Engineering Performance CHOATE Part Number:CEP59CSW0304

5.9L Cummins Workhorse Short Block Engine Includes:

• New Freeze Plugs
• Rear Main Seal
• Surfaced to exceed Ra finish for MLS Gaskets
• New Tappets
• New Pin Retainers
• Balanced and weight matched Rotational Assembly (See Video)
• OE Crank Flange Bolts
• New Rod Bearings
• New Main Bearings
• New Cam Bearings
• Install Rear Main Seal
• Install New Rear Cover Gasket
• Install Upper Oil Pan
• Install Lower Oil Pan
• Billet Freeze Plugs  (See Video)
• Install Pickup Tube O-ring
• Coated, Flycut, and Delipped G3 Pistons (See Video)
• 5 year/100k Mile Warranty

Machining Processes Include:

• Full CNC blue print machining, (bore, deck, hone and line honed) (See Video)
• The Cylinder bores are blue print bored to a true 90 degrees over the crankshaft center line
• Diamond honed to within .0002 inch for precise piston to cylinder bore clearance  (See Video)
• Bored and line hone the crank bore housing to precisely align the crankshaft in the engine block.
• Torque Plate Honed  (See Video)
• The piston diameter measured to the nearest .0001 inch matched to cylinder bores.
• The Cylinder block is surfaced to a finish of RA30 or lower, which meets the factory specification in both flatness and smoothness for the block to head sealing surface.  (See Video)
• This is mandatory for proper sealing of a MLS Gasket.

Piston Cracking is a Common Failure with the 5.9L Cummins Engines, Cass talks a bit about the G3 Pistons in all our WorkHorse builds!

Billet Freeze Plugs made in house at Choate Engineering Performance

What is “Blueprint Boring” anyways? And how we acheive this!

This is why we square deck the block!

This is why we balance the rotational assembly!

This is why we torque plate hone!

Why we only use the Rottler hone for YOUR engine!

Why do we encourage you to buy a long block instead of a short block?

On the fence on which engine you should buy? Daily Driver VS WorkHorse Engine.

Check out this video with Cass. He explains the issues and the fixes of the Cummins platform. (And How we fix them.)

Cylinder Heads- While there aren’t as many issues with the bottom end of the Cummins, there are really BIG problems in the head department.

Valve seats fallout contacting the piston and cause catastrophic failure. We machine oversize valve seats within creased press fit area to remedy this issue.

Stamped gallery plugs in the heads blow out causing a mixture of oil and coolant, destroying the bearings. We thread the head and insert threaded plugs to make sure this issue never rears its ugly head.

Plus: Freeze plugs in the block blow out leaving you at best stranded on the side of the road, at worst, with a severely overheated engine in need of remanufacturing. Every new Choate Cummins engine comes standard with billet freeze plugs that are blow out proof using a tie bar bolting them into the side of the block.

Assembled by Our Professional Team in house

The WorkHorse build is meant for constant towing and heavy duty applications. It is engineered to endure hard work at a consistent level. If you are a rancher, a farmer, hotshotter, or need something to pull Mt. Everest, the Workhorse is the build for you.

• Upgrades over the Daily Driver include but are not limited to:

• Choate G3 Pistons
• Performance Stage 2 Camshaft 
• Welded Cam Gear 

Common Issues With The Dodge Cummins 5.9L Engine (and how we fix them)

• Cylinder Heads- While there aren’t as many issues with the bottom end of the Cummins, there are really BIG problems in the head department.
• Valve seats fail contacting the piston and cause catastrophic failure.
• We machine oversize valve seats within creased press fit area to remedy this issue.
• Stamped gallery plugs in the heads blow out causing a mixture of oil and coolant, destroying the bearings.
• We thread the head and insert threaded plugs to make sure this issue never rears its ugly head.
• Freeze plugs in the block blow out leaving you at best stranded on the side of the road, at worst, with a severely overheated engine in need of remanufacturing.
• Every new Choate Cummins engine comes standard with billet freeze plugs that are blow out proof using a tie bar bolting them into the side of the block.

Optional Parts are not installed. Optional parts are covered under the manufacturer’s warranty and not by CHOATE.