03/04 = 305hp 555tq, smaller turbo, 3 1/2" downpipe, 8 hole injectors w/143* spray angle, 2 injection events. Some 03/04 were non HO's, 235hp/250hp, auto trans 47RE vs 48RE in the HO's.
04. 5 = 325hp 600tq(610tq?) larger Holset turbo, full 4" exhaust w/cat, 5 hole injectors w/124* spray angle, 3 injection events. 05's had plastic intercooler caps that crack.
The pistons are slightly different, not exactly sure, oil cooling and different bowl design. It appears most 03/04 owners believe their trucks superior, and 04. 5 owners believe likewise, go figure:-laf:-laf. I believe I would be happy with either, even the non-HO's.