5.9 Cummings leaking water

[tg in VA]

I have a 1999 Dodge 3500 with the 5.9 Cummings. Over the summer, it developed a slow coolant leak.
My diesel mechanic was unable to locate it and I have been adding coolant periodically. Saturday, I was hauling a horse to a barn about 160 miles away. I checked and filled to coolant before leaving. About 95 miles into the trip the truck began to overheat. I stopped and added 2 1/2 gallons of water. 10 miles later, it was overheating again. I stopped at a truck stop and they found a hairline crack in the block just above the freeze plug on the right side (front) of the engine. I had lost over 2 gallons of coolant in 10 miles. We added a bottle of Barrs Stop Leak and I delivered the horse and brought two horses back without overheating. However, the coolant level is down today.
My question for you guys is, is this repairable or do I need to dump the truck and find something else to use in my equine hauling endeavors? As you all probably know, no one will tow you if you have a trailer containing live animals.
Help!!! Thanks.

 

[Davis In SC]

There was one type/# of block that is subject to cracking. I think most can be repaired by Metal Stitching. The crack is fairly common. It might be worth asking if Cummins would assist in paying for the repairs..

 

[Greg_Ky]

Common problem with the Cummins.
Locknstitch Repair

 

[Anonymous-0]

I have seen that crack on cummins engines at the Dodge dealership where I worked. I inquired as to the best repair. What I was told is that the engine needs to be stripped down and placed in an oven and heated and then repaired and then use controlled cooling. I ended up replacing the long block.
Ted

 

[ToddLevi]

It is a common problem. My fathers motor home did this at 27k miles. He had an extended warranty but they did not want to pay for it because they said it was a cummins factory defect. Cummins said it wasn"t their problem because the motor was out of warranty. In the end both helped replace the block but my father still had to pay $1700. A new block is about the only way to fix it because it is a stress cast into the 53xxx? series blocks. The crack will stop when a piece falls out of the block.

 

[Anonymous-0]

That's the darndest thing I ever saw.

 

[Mike M]

I didn't know about that not being able to get towed with live animals thing. Good to know. Is this because of some liabilty thing ?

 

[Anonymous-0]

yup, you have a 53 block. Use the lock-n-stitch and you'll be good for another 250,000