Product Description
CUMMINS 3904166 OEM CYLINDER REPAIR SLEEVE (SALVAGE SLEEVE) – 5.9L 4BT/6BT/ISB (1989–2007)
The genuine Cummins 3904166 salvage sleeve is the OEM solution for rescuing worn, scored, or damaged cylinders in 3.9L and 5.9L B-Series/ISB engines. Instead of scrapping a block, this straight (non-flanged) cylinder repair sleeve lets your machine shop return the bore to standard size and restore compression, ring seal, and long-term durability on work trucks, tow rigs, and industrial B-Series engines.
Why Choose the Cummins 3904166 Salvage Sleeve?
- Genuine Cummins engineering for correct material hardness, wall thickness, and interference fit.
- Restores damaged cylinders to standard bore so you can run standard pistons and ring sets.
- Straight, non-flanged design for conventional machine-shop boring, pressing, and finish-honing.
- Ideal when typical oversize rebores won’t fully clean up scoring, taper, or cavitation damage.
- Often the most cost-effective way to save an otherwise good 4BT/6BT/ISB 5.9L block.
Verified Automotive Fitment – Dodge/Ram 5.9L Cummins
This Cummins salvage sleeve is used extensively on 5.9L ISB and B-Series applications, including Ram trucks from 1989–2007.
- 1989–1993 – 5.9L 12-Valve 6BT, Dodge Ram 2500/3500
- 1994–1998 – 5.9L 12-Valve 6BT (P7100 mechanical injection), Ram 2500/3500
- 1998.5–2002 – 5.9L 24-Valve ISB (VP44), Ram 2500/3500
- 2003–2007 – 5.9L 24-Valve ISB (common-rail), Ram 2500/3500
Industrial / Off-Highway: Commonly used on B3.9/4BT and B5.9/6BT engines, plus ISB/QSB 5.9 industrial variants. Always confirm by ESN (Engine Serial Number) and your machine shop’s recommendation for non-automotive applications.
Important: This sleeve is for the 102 mm standard-bore 5.9L B-Series family. It is not correct for 6.7L Cummins (107 mm bore).
Best Use Cases
- Severe scoring or gouging that won’t clean up with a standard oversize bore.
- Localized damage in one or two cylinders (dusting, melted piston, foreign-object damage, etc.).
- Block repair on high-mileage work trucks where a new or reman block isn’t in the budget.
What’s Included
- (1) Genuine Cummins cylinder repair sleeve – Part #3904166
Recommended Genuine Cummins Companion Parts
Pair this salvage sleeve with other Cummins OEM parts to complete a proper repair:
- CUMMINS 3957544 OEM ENGINE OIL COOLER – 6BT/ISB 5.9L (1989–2002)
- CUMMINS 5292742 OEM 180° THERMOSTAT – 5.9L ISB (1998.5–2007) | 4BT
- CUMMINS 3931623 OEM VALVE TAPPET (LIFTER) – 6BT/4BT 5.9L/3.9L (1989–1998)
- CUMMINS 4939587 OEM ENGINE OIL PUMP – 5.9L 12V/24V (1989–2002)
Technical Highlights
- Part Number: 3904166
- Engine Families: 4BT/6BT, B3.9/B5.9, ISB/QSB 5.9
- Bore Family: 5.9L B-Series, standard 102 mm bore
- Design: Straight, non-flanged salvage sleeve
- Quantity: 1 sleeve per repaired cylinder (order one per damaged bore)
Installation Notes (Machine Shop Required)
- Measure taper, out-of-round, and damage to verify a salvage sleeve is the correct repair.
- Block is bored to the correct outside diameter for the sleeve interference fit.
- Sleeve is installed by a qualified machine shop, then finish-honed to the final piston-to-wall clearance.
- Always check piston and ring part numbers against the final bore size and target application.
- Thoroughly clean oil and coolant passages before reassembly and break-in.
FAQ
WILL THIS FIT MY 1989–2007 5.9L CUMMINS RAM?
Yes. This salvage sleeve is widely used to repair 5.9L B-Series/ISB engines in 1989–2007 Ram 2500/3500 trucks. Always confirm by engine serial number and consult your machine shop before ordering.
CAN I USE THIS SLEEVE IN A 6.7L CUMMINS?
No. The 6.7L Cummins uses a larger 107 mm bore. Cummins 3904166 is engineered for the 102 mm 5.9L B-Series/ISB family only.
IS THIS A FLANGED OR STRAIGHT CYLINDER SLEEVE?
It is a straight, non-flanged salvage sleeve. The block is bored for the sleeve, the sleeve is pressed in with the proper interference fit, and the cylinder is finish-honed to spec.
DO I REALLY NEED A MACHINE SHOP TO INSTALL IT?
Yes. Proper boring, pressing, and final honing are critical to ring seal, piston clearance, and long-term durability. This is not a DIY drop-in sleeve.
WHAT OTHER PART NUMBERS CROSS TO CUMMINS 3904166?
Common cross-reference numbers in the industry include Cummins 3900396 and 3903412, plus aftermarket equivalents such as DS557, ML157, M-3904166, and PAI 161630-090. These are listed for reference only; this product is the genuine Cummins 3904166 salvage sleeve.
HOW MANY SLEEVES SHOULD I ORDER?
Order one salvage sleeve per cylinder that requires repair. If multiple bores are damaged, your machine shop may recommend sleeving more than one hole to keep clearances consistent.
Specifications for cummins 3904166
| Brand | Cummins |
| Part Number | 3904166 |
| Product Type | OEM cylinder repair sleeve (salvage sleeve), straight non-flanged |
| Engine Compatibility | Cummins 4BT/6BT B3.9/B5.9, ISB/QSB 5.9, automotive 5.9L Ram 2500/3500 (1989–2007) |
| Bore Size Family | Standard 5.9L B-Series 102 mm bore |
| GTIN | 0602463141667 |
| UPC | 0602463141667 |
| Shipping Weight | Approx. 1.9 lb (single sleeve) |
| Package Dimensions | Approx. 5.25 in x 5.25 in x 10.18 in (single sleeve carton) |
| Shipping Method | Standard ground; ships from CPP Diesel |
| Hazardous Material | Non-hazardous diesel engine component |
| Cross Reference | Cummins 3900396, Cummins 3903412, DS557, ML157, Interstate-McBee M-3904166, PAI 161630 / 161630-090 |
| E-Codes | Not applicable (engine internal component) |
| Prop 65 | May expose you to chemicals found in metal engine components; handle used engine parts and fluids with care in accordance with California Proposition 65 guidelines. |
