Product Description
Cummins 3904166 — Genuine Cylinder Repair Sleeve (Salvage Sleeve) for 5.9L B-Series
MPN: 3904166 | Also Known As: salvage sleeve, cylinder liner repair sleeve (straight, non-flanged) | Application: B-Series 3.9L/5.9L service repair
Genuine Cummins cylinder repair sleeve designed to restore worn or damaged bores to standard size on B-Series engines. Ideal when an oversize rebore won’t clean up the cylinder. Automotive coverage: 1989–2007 Ram 5.9L (12V, VP44 24V, and common-rail). Sold individually (order one per affected cylinder).
Features & Benefits
- OE salvage solution to return a damaged cylinder to standard size and compression.
- Straight, non-flanged sleeve for machine-shop installation and finish-hone to spec.
- Protects performance by reducing blow-by, oil consumption, and hot-spotting from scored walls.
- Engineered by Cummins for correct material hardness and wall integrity.
- Cost-effective block save when compared with replacement or sleeving all six.
Verified Fitment (Automotive)
| Year Range | Engine | Chassis |
|---|---|---|
| 1989–1993 | 5.9L 12V (6BT) | Ram 2500/3500 |
| 1994–1998 | 5.9L 12V (6BT) | Ram 2500/3500 |
| 1998.5–2002 | 5.9L 24V ISB (VP44) | Ram 2500/3500 |
| 2003–2007 | 5.9L 24V ISB (Common-Rail) | Ram 2500/3500 |
Industrial/Off-Highway: B3.9/4B3.9 and B5.9/6B5.9 families; also listed for ISB/QSB 5.9 variants — verify by ESN for non-automotive use.
Compatibility Notes:
- Intended for 5.9L (102 mm bore) B-Series platforms. Not for 6.7L engines (107 mm bore).
- Machine shop install required: bore for sleeve, press/interference fit with sealant as specified, then finish-hone to piston clearance.
- Best results when paired with new piston/rings in the repaired cylinder.
Specifications
- Type: Straight (non-flanged) cylinder repair sleeve / salvage sleeve
- OE Part Number: 3904166
- Engine Families: 4B3.9 / 6B5.9 (ISB/QSB 5.9)
- Quantity Required: 1 per repaired cylinder (sold individually)
- Bore Family: 5.9L B-Series standard bore (102 mm)
Often Paired With
- Pistons & ring sets matched to final bore
- Head gasket set (recommended during top-end reassembly)
- Coolant & oil refresh after machining and cleaning
What’s In The Box
- (1) Genuine Cummins Cylinder Repair Sleeve (3904166)
Installation Tips
- Measure wear and out-of-round; confirm oversize rebore won’t clean up before choosing a salvage sleeve.
- Follow Cummins/machine-shop procedures for sleeve interference fit, adhesive/sealant (if specified), and deck integrity.
- Final hone to target piston-to-wall clearance; verify ring end-gaps.
- Thoroughly clean block oil/coolant passages before reassembly.
FAQ
WILL THIS FIT MY 5.9L CUMMINS RAM (1989–2007)?
Yes—3904166 is used to repair cylinders on 5.9L B-Series/ISB engines across 1989–2007 Ram applications. Confirm by ESN and machine-shop assessment.
IS THIS THE RIGHT SLEEVE FOR A 6.7L CUMMINS?
No. The 6.7L uses a larger 107 mm bore; 3904166 targets 5.9L (102 mm bore) engines.
IS IT FLANGED OR STRAIGHT?
Straight (non-flanged) salvage sleeve—installed with an interference fit and finish-honed to spec.
DO I NEED A MACHINE SHOP?
Yes. Proper boring, pressing, and final honing are required for service life and sealing.
WHEN SHOULD I CHOOSE A SALVAGE SLEEVE?
Use a salvage sleeve when a standard oversize rebore (e.g., +0.040") won’t remove scoring/taper, or to save a block with localized damage.
