Banks Power Dodge Trucks: (Diesel ’03 - 07 5.9L Cummins) Intake- Big Hoss Intake Manifold System '03-07 235, 250, 305 and 325 HP, Dodge Cummins 5.9L (24-valve) Trucks - Manual (Page 6)

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96774 v.5.0
Turn the cylinder head over
so the head gasket surface
faces up. Once again locate the
front head bolt dowel hole and
corresponding row of seven head
bolt holes. From an accurate
location of the centerline of this
row of head bolt holes, measure
and scribe a reference line the
length of the head 5.670 inches
[144mm] toward the intake port
side of the head. This line will
be the corner intersection of the
head gasket surface and the new
intake manifold seal surface. (See
Figure 2)
The intake manifold seal surface
must be machined at an 85°
angle to the head gasket surface
(5° off a vertical when installed
on the engine). The machining
may be done using a block/head
surfacer or a milling machine
with enough table travel to cover
the length of the head. The cut
will likely require a number of
passes to reach the finished
dimension at the 85° angle. (See
Figure 3) The finished surface
cut should come to or be just
below the rocker cover gasket
rail surface on the intake face of
the head. 100% clean-up of the
as-cast head below the rocker
cover rail flange is not required.
-EnD, SEcTion 4-
Section 4
MACHINING MANIFoLD FACe
FRONT HEADBOLT
DOWEL HOLE
BANDSAW
ROUGH CUT
5.670
144 mm
CORNER INTERSECTION
OF 85° ANGLE
85°
HEAD GASKET
SURFACE
TOP OF
HEAD
FINAL SURFACE
TO BE MACHINED
Figure 2