24V Cummins Head Stud Installation Guide (5.9L & 6.7L, 1998.5–Present) — CP876

This guide covers installation of the XOTIC PERFORMANCE™ CP876 head stud kit for the 1998.5–present 5.9L and 6.7L 24V Dodge Cummins diesel. It covers the three-stage torque specs, which positions take the longer studs, and the rocker cover clearance note that catches people off guard. Prefer a printable copy? Download the PDF manual.

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Why the 24V Cummins needs head studs

Factory OEM head bolts are torque-to-yield: you torque them to a specified value, then add a final 90° rotation that stretches the bolt to its maximum point. That works at stock power levels. But when you add parts that increase horsepower — a turbocharger, injectors, a tuner — you create higher cylinder pressures lower in your RPM range, and the clamping force securing the gasket, head, and block is no longer sufficient. The result: a blown head gasket.

Head studs are engineered to resist stretching. XOTIC PERFORMANCE™ head studs are manufactured from our premium XOTIC 7200 steel alloy, superior in tensile strength to any bolt, and backed by a lifetime warranty. The key to getting that strength into your engine is accurate preload — the tensile force generated when a fastener is tightened, creating clamp force in the joint. Everything in this guide is in service of achieving equal, accurate preload on all 26 fasteners.

What's in the CP876 kit

• 20 × head studs, M12 × 160mm (XOTIC 7200 alloy)
• 6 × head studs, M12 × 168mm
• 26 × hardened parallel washers
• 26 × nuts
• 1 × socket
• 1 × allen wrench
• 1 × fastener assembly lubricant

Before you start: verify first

Confirm that part number CP876 is compatible with your application (1998.5–present 5.9L or 6.7L 24V Dodge Cummins) before installing any components. Inspect all package contents and clean as necessary to ensure accurate installation. Report any obvious defects or shipping damage to us before proceeding.

How to install head studs on a 24V Cummins

1. Clean the block threads. Clean the threads in the block prior to installing the head studs to ensure accurate fitment and precise torque readings. A dedicated M12 x 1.75 thread chaser (CS304) makes this fast and protects the threads.
2. Install the studs hand-tight — long studs in the right holes. Thread the head studs into the block by hand until snug; do not apply torque. Install the six 168mm studs into positions #3, 6, 11, 14, 19, and 22 as shown in the manual's diagram, and the 160mm studs in the remaining holes.
3. Check stud height with a straightedge. Use a straightedge ruler to measure the distance from the mating surface (deck or main cap) to the top of each installed stud. Ensure all studs of the same length group sit level with each other (within 1 mm / 0.040”). Uneven height may indicate debris or incorrect thread engagement. Properly installed studs will bottom out smoothly and show uniform height across all positions. If a stud appears higher or lower than the others, remove it, re-clean the hole, and reinstall by hand. Do not use tools to force studs deeper. Incorrect stud seating can cause off-angle stress, uneven preload, or stud fracture during engine operation.
4. Set the gasket and head. Install the head gasket and cylinder head, ensuring proper alignment.
5. Clean the washer seating areas. Clean the washer seating surfaces on the cylinder head with a fast-evaporating solvent such as non-chlorinated brake cleaner to remove oil, grease, and contaminants. A clean surface is essential for achieving proper fastener preload.
6. Lubricate. Place the washers onto the studs. Using the supplied assembly lubricant, apply a thin coat to the stud threads, the underside of the nuts, and the top side of the washers.
7. Install the nuts. Thread the nuts onto the studs and hand-tighten until they make contact with the washers.
8. Torque in sequence. Follow the torque stages below, tightening nuts 1–26 in the numbered sequence shown in the manual's torque sequence diagram.

24V Cummins head stud torque specs

Frequently asked questions

What are the torque specs for 24V Cummins head studs?

Three stages, applied to all 26 nuts in sequence: 45 ft-lbs, then 90 ft-lbs, then a final pass at 125 ft-lbs.

Do the 5.9L and 6.7L Cummins use the same head studs?

Yes — the CP876 kit fits 24V Cummins engines from 1998.5 to present, covering both the 5.9L and the 6.7L.

Which positions get the longer 168mm studs?

Positions #3, 6, 11, 14, 19, and 22 take the six M12 × 168mm studs. The remaining 20 positions use the 160mm studs.

Do I need to modify anything to install head studs on a 24V Cummins?

One spot: the lower rocker arm cover needs material removed at position #24 to clear the stud, washer, and nut. The manual's diagram highlights exactly where to machine.

Doing the full engine?

If the head is off, it's the cheapest time you'll ever have to do the bottom end. The Head & Main Stud Combo Kit (CP876-MP876) pairs these head studs with MP876 main studs for the 1997.5–2006 5.9L in one kit.

Need help?

For technical support, email support@xotic-performance.com. All XOTIC PERFORMANCE™ fasteners are covered by our limited lifetime warranty. Finished your install? Tag #XOTICPERFORMANCE on Instagram for a chance to be featured.

© 2026 XOTIC PERFORMANCE™. This installation guide is an original copyrighted work of XOTIC PERFORMANCE™. Reproduction, distribution, or use of this content in whole or in part without written permission is prohibited. Doc ref: 2025.05.27 (web edition 2026.08).