Product Description
Interstate-McBee M-4089977 Piston Kit – .040" Oversize (1.00 mm) – 2003–2004 5.9L Cummins 24-Valve 305 HP
Aftermarket OE-style piston kit engineered for the 2003–2004 5.9L Cummins 24-valve (common-rail) engines rated at 305 HP. This kit is .040" oversize (1.00 mm) and is intended for cylinders that have been bored and honed to the corresponding service size. Sold individually (per cylinder).
- Direct replacement: Matches OE form, fit, and function where Cummins 4089977 is specified.
- .040" oversize: For reman builds requiring 1.00 mm overbore; ring set is sized to match.
- Balanced performance: Designed for smooth operation with stock rods and factory compression characteristics (verify by ESN).
- Complete kit: Includes piston, rings, wrist pin, and pin retainers for one cylinder.
- Interstate-McBee quality: Trusted aftermarket components for reliability and value.
Specifications
| Brand | Interstate-McBee |
| Part Number | M-4089977 |
| Oversize | .040" (1.00 mm) |
| Engine | 5.9L Cummins 24-valve (common-rail) |
| Model Years | 2003–2004 (305 HP calibration) |
| Sold As | Each (per cylinder) |
| Qty Required | 6 kits for a complete engine |
| Includes | Piston, ring set, wrist pin, pin retainers (circlips) |
Vehicle Fitment
Always confirm by engine serial number (ESN) and parts catalog data for your specific build.
- Dodge Ram 2500/3500 with 5.9L Cummins 24-valve common-rail
- Years: 2003–2004 (305 HP rating)
- Other applications using Cummins reference 4089977 (verify by ESN).
What’s Included (Per Cylinder)
- (1) Piston – .040" oversize (1.00 mm)
- (1) Piston ring set – matched to oversize
- (1) Wrist pin
- (2) Pin retainers (circlips)
Recommended/Related Parts
- Head gasket set and lower gasket set
- Rod bearings and main bearings
- Oil pump and piston cooling nozzles (inspect/replace as needed)
- Head bolts or studs
- Ring compressor, plastigage, and assembly lube for installation
Install Notes
- Machine work required: Cylinders must be bored and honed to the correct .040" oversize with proper finish for ring seating.
- Measure everything: Verify piston-to-wall clearance, ring end gap, and pin fit per service manual specs.
- Match components: Keep each piston/ring set with its cylinder; check weight class markings if applicable.
- Cleanliness matters: After machining, thoroughly clean cylinders to remove abrasive residue.
- Follow torque/angle specs: Use the factory service manual for clearances and fastener procedures.
Why Buy From CPP Diesel
- ESN-verified fitment support from diesel specialists
- Fast shipping and hassle-free returns
- Deep inventory for full 5.9L Cummins rebuilds
FAQ
Is this kit for one cylinder or all six?
This listing is sold per cylinder (one piston kit). Order six kits for a complete engine.
Will .040" pistons work without machining?
No. .040" (1.00 mm) oversize pistons require the block to be professionally bored and honed to the matching service size.
Does this fit 2004.5–2007 (325 HP) engines?
This kit targets the 305 HP calibration. Some late-2004 and later engines use different components; verify by ESN before ordering.
