5.9L 03-04 Cummins Long Block Workhorse Dodge Ram Diesel Crate Engine Choate Performance

The Workhorse model is specifically designed for the working man who requires maximum durability and reliability for regular heavy hauling and strenuous towing. 5.9L 03-04 Cummins Long Block Workhorse Dodge Ram Diesel Crate Engine.

Key Features and Fixes:

Upgrades Over the Daily Driver:

• O-Ringed Heads
• Coated, Fly Cut and Delipped Pistons
• Stage 2 Cam
• Chromoly Pushrods

Core Performance and Power:

• High-Output Performance: Rated for 600 Plus HP capability, delivering significant power over stock for demanding applications.
• Fully Balanced Rotating Assembly: Precision-balanced components ensure smooth, vibration-free operation and extended bearing life at high RPMs.

Reliability and Durability Upgrades:

• Maxxforce Style Pistons: Upgraded pistons that are inherently stronger and designed for more robust commercial applications. This solves the OEM issue of weak pistons that are prone to cracking under heat and boost. The Workhorse takes this a step further with Coated, Flycut, and Delipped pistons for maximum thermal resistance and durability.
• Enhanced Valve Integrity: Features all-new, upgraded material valves that eliminate the high-heat separation common in OEM exhaust valves, preventing compression loss and piston-to-valve contact.
• Improved Head Sealing: O-Ringed heads provide a superior seal, essential for maintaining integrity under high cylinder pressures.
• Stage 2 Valvetrain and Drivetrain: Equipped with a Stage 2 Camshaft and Chromoly Pushrods for enhanced strength.

Machining Process:
Choate Engineering Performance doesn't just rebuild engines - we remanufacture them. Each of our engines undergoes extensive, precision machine work to correct OEM flaws and ensure durability and reliability.

Engine Block Machining:
Each of our engine blocks are CNC blueprint machined using state-of-the-art CNC machines. This process ensures perfect dimensions, precise tolerances, and optimal alignment. This starts with decking the surface of the block to achieve the necessary flatness and smoothness (Ra 30 or better) required for flawless sealing with MLS head gaskets.

The cylinders are then diamond honed to an extremely tight tolerance to match the piston diameter (within the nearest 0.0001 inch). Following honing, the main bearing bores are line honed to establish a true, straight centerline for the crankshaft. Finally, the cylinder bores are bored to a true 90 degree angle from the crankshaft centerline.

Cylinder Head Machining:
Our cylinder heads are fully machined and enhanced in-house to improve airflow and reliability. Each head is first magnafluxed and pressure tested to ensure they are free of any cracks or leaks. The surface is then precision decked to an extremely smooth finish, guaranteeing the necessary flatness for a perfect seal with MLS head gaskets.

For enhanced durability, o-rings are cut and installed into the deck surface to dramatically improve sealing under high cylinder pressures. Internally, the valve seats are machined to optimize airflow and prevent common failures, and the entire valve train geometry is blueprinted to specific tolerances to reduce lifter preload and prolong component life.

Rotational Assembly Balancing:
The balancing of the rotational assembly is crucial for eliminating vibration and maximizing engine longevity. This precision work involves checking and correcting the balance of the crankshaft, connecting rods, and pistons. The crankshaft is thoroughly checked for run-out and inspected for fatigue before being polished and ground to strict concentricity tolerances (0.0005 or less) to ensure the new bearings receive the best possible surface.

Rods are inspected and conditioned, and all bearing clearances checked to ensure proper fitment with the new bearings. Each of the pistons, rings, and pin retainers are meticulously weight matched (to a tolerance of 2 grams or less) prior to crank balancing. Then the entire assembly is dynamically balanced on specialized equipment. This ensures that the engine runs smoothly, minimizing stress on the bearings, and extends the overall life of the components.

Components and Parts:

Engine Core Components:

• Cylinder Block
• Crankshaft
• Steel Connecting Rods
• Stage 2 Camshaft
• Coated, Flycut, and Delipped Pistons
• O-Ringed Cylinder Head
• Chromoly Pushrods
• New Main Bearings
• New Rod Bearings
• New Cam Bearings
• Main Bolts
• Head Studs
• Rockers
• Billet Freeze Plugs
• New Oil Pump
• Upper Oil Pan
• Lower Oil Pan

Gaskets and Seals:

• New Head Gaskets
• Rear Main Seal and Housing
• Front Gear Housing

Cylinder Head Components:

• O-Rings
• New Valve Guides
• New Socket Plug
• New Oversized Valve Seats
• New Threaded Plugs