Your 5.9 Cummins is a workhorse, no doubt. Maybe you’re hauling heavy loads for work, or perhaps you just enjoy the raw power and sound it offers. But lately, you’ve noticed it’s not quite performing like it used to. Maybe the acceleration is sluggish, or you’re just not getting the same kick you once did. It’s a feeling many 5.9 Cummins owners experience eventually, and the good news is, there’s a solution: upgrading your turbo.
Finding the right turbo can feel overwhelming, with countless options and technical jargon to wade through. That’s where we come in. This article is your comprehensive guide to the best turbo upgrades for 5.9 Cummins, breaking down the top choices on the market. We’ll provide detailed reviews, highlight key features, and offer expert advice to help you choose the perfect upgrade for your specific needs and budget. Let’s get your Cummins roaring back to life!
We will review the best turbo upgrades for 5.9 cummins later in this article. But before that, take a look at some relevant products on Amazon:
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Unleash the Beast: Finding Your Perfect 5.9 Cummins Turbo
So, you’re looking to breathe some serious fire into your 5.9 Cummins? You’re in the right place! Let’s be honest, the stock turbo is decent, but it’s like a well-mannered housecat compared to the roaring lion your Cummins can truly be. We’re talking about unlocking hidden horsepower, improving throttle response, and potentially even seeing better fuel economy. Think of it as giving your trusty workhorse the lungs of a marathon runner.
Why even bother with turbo upgrades? Well, for starters, the factory turbo is designed for reliability and emissions, not necessarily peak performance. Upgrading allows you to tailor your truck’s power delivery to your specific needs. Towing heavy loads? A larger turbine can help maintain boost at lower RPMs. Chasing quarter-mile times? A turbo with a quicker spool-up time might be your best bet. Did you know that upgrading to a larger turbo can potentially increase horsepower by 100-200, or even more, depending on supporting modifications?
But hold your horses (pun intended!). Choosing the best turbo upgrades for 5.9 Cummins can feel overwhelming. There’s a whole alphabet soup of terms like “turbine A/R,” “compressor inducer,” and “wastegate” that can make your head spin. Don’t worry, we’ll break it all down. This isn’t just about slapping on the biggest, baddest turbo you can find. It’s about finding the right turbo that matches your driving style, intended use, and budget.
Think of this guide as your friendly pit crew, helping you navigate the world of turbochargers and select the perfect match for your Cummins. We’ll explore different turbo types, discuss the pros and cons of each, and help you understand the supporting modifications needed to make your upgrade a success. Get ready to unleash the true potential of your 5.9!
Best Turbo Upgrades For 5.9 Cummins – Reviews
BorgWarner S366
Looking for a turbo that can deliver serious power without breaking the bank? The BorgWarner S366 might be just the ticket. This turbocharger is a popular choice for a reason: it’s a robust, reliable, and relatively affordable upgrade for your 5.9 Cummins. You’ll see a noticeable improvement in spool-up and top-end power, making it a great all-around performer for both daily driving and towing.
While it’s not the absolute biggest turbo you can bolt onto your Cummins, the S366 strikes a sweet spot. It’s responsive enough for street use and still capable of supporting enough airflow for 500+ horsepower with the right supporting mods. Keep in mind that you might need to upgrade your injectors and fuel pump to really unleash its full potential.
Steed Speed T4 Manifold with Garrett GT4202
The Steed Speed T4 manifold paired with a Garrett GT4202 is a combo designed for serious performance gains. This isn’t just a bolt-on upgrade; it’s a commitment to transforming your Cummins into a powerhouse. The Steed Speed manifold is known for its exceptional flow characteristics and durability, optimizing exhaust gas delivery to the turbo. The Garrett GT4202, a larger frame turbo, can support significant horsepower numbers.
This setup is for those aiming for the higher end of the power spectrum, targeting 600+ horsepower. Be aware that it requires supporting modifications to maximize its potential and manage the increased airflow. Upgrades like larger injectors, a beefier fuel pump, and potentially head studs are likely necessary. It’s a serious upgrade for those who want to push their Cummins to the limit.
BD Diesel Super B Special
The BD Diesel Super B Special is designed to offer a balance between improved performance and driveability. It’s a modified version of the popular Holset turbocharger, tweaked by BD Diesel to deliver quicker spool-up and enhanced airflow compared to the stock unit. This makes it a great upgrade for daily drivers and those who tow frequently.
This turbo shines by giving you a broader powerband. You will experience less turbo lag than many larger aftermarket options, making it more responsive in everyday driving situations. While it may not support the extreme horsepower numbers of some larger turbos, the Super B Special offers a noticeable improvement over stock, making it a worthwhile upgrade for a truck that sees both work and play.
ATS Aurora 3000
Looking for a turbo that can handle daily driving while still delivering a good kick when you need it? The ATS Aurora 3000 is a solid choice. It’s designed as a direct replacement for the factory turbo, simplifying the installation process and minimizing downtime. You’ll appreciate the quicker spool-up and increased airflow, resulting in improved throttle response and overall performance.
The Aurora 3000 provides a noticeable bump in power without sacrificing street manners. It’s a great option for those who want to upgrade their turbo without needing to make a ton of other modifications. While it may not be the best choice for all-out competition, it offers a significant improvement over the stock turbocharger, making it ideal for everyday use and light towing.
Industrial Injection Silver Bullet 66
The Industrial Injection Silver Bullet 66 is designed to deliver a potent blend of performance and reliability for your 5.9 Cummins. This turbo is capable of supporting substantial horsepower gains while maintaining good drivability. It’s a popular choice for those seeking a significant upgrade that won’t compromise the daily usability of their truck.
With the Silver Bullet 66, you can expect quicker spool-up and increased airflow, resulting in improved throttle response and overall performance. It’s a great option for those aiming for power levels in the 600-700 horsepower range. While it performs well on its own, remember that optimizing its performance requires supporting modifications, such as larger injectors and a performance fuel pump.
Why Upgrade Your 5.9 Cummins Turbo?
Ever feel like your trusty 5.9 Cummins is just a little…sluggish? Maybe you’re towing a heavy load uphill and it’s struggling, or perhaps you’re just looking for a more responsive and exhilarating driving experience. The stock turbo on the 5.9 Cummins is a solid unit, but it’s designed to meet factory specifications and fuel economy targets, leaving potential performance on the table. Think of it like wearing shoes that are a size too small – they work, but they’re not exactly optimized for comfort or performance when you’re trying to run a marathon!
The “best turbo upgrades for 5.9 Cummins” are designed to unleash the true potential of your engine. They offer improved airflow, leading to faster spool-up, reduced turbo lag, and increased horsepower and torque. Imagine accelerating onto the highway with confidence, knowing you have the power to pass anyone with ease. Or picture towing that boat to the lake without feeling like you’re battling a losing war against gravity. That’s the kind of performance boost a well-chosen turbo upgrade can provide.
Beyond the raw power, upgraded turbos can also improve overall engine efficiency and longevity. By allowing your engine to breathe easier, they reduce stress on other components and can even lead to better fuel economy when not under heavy load. Think of it as giving your engine a lung transplant – it can breathe deeper, work less hard, and last longer. Plus, the deeper, more aggressive sound of a performance turbo adds a touch of excitement to every drive.
Ultimately, upgrading your 5.9 Cummins turbo is about unlocking the potential within your engine and tailoring your truck to your specific needs and desires. Whether you’re a hardcore enthusiast seeking maximum horsepower or a daily driver looking for improved towing performance and responsiveness, the “best turbo upgrades for 5.9 Cummins” can transform your driving experience and give you a truck that truly lives up to its legendary reputation. Don’t settle for “good enough” when you can have “exceptional.”
Understanding the 5.9 Cummins Turbo System
Let’s face it, the stock turbo on a 5.9 Cummins is reliable, but it’s not exactly setting any performance records. It’s designed for efficiency and longevity, which is great for everyday driving and light towing. However, if you’re craving more power or planning on hauling heavier loads, it can quickly become a bottleneck. Think of it like this: the stock turbo is like a comfortable pair of work boots – dependable, but not exactly suited for a marathon.
The factory turbo’s limitations stem from its size and design. It’s simply not capable of flowing enough air to support higher horsepower levels. When you try to push it harder, you’ll likely encounter increased exhaust gas temperatures (EGTs) and potentially premature wear and tear. Picture trying to breathe through a straw while running a sprint – you’ll quickly run out of breath and be forced to slow down.
Upgrading your turbo is like upgrading your lungs, allowing your engine to breathe easier and generate more power. By increasing airflow, you can burn fuel more efficiently, resulting in increased horsepower and torque. Plus, a properly sized turbo will help keep EGTs in check, preventing potentially damaging engine issues.
Ultimately, understanding the stock turbo system’s limitations is crucial for making informed upgrade decisions. Knowing where it falls short will help you choose a replacement that meets your specific needs and performance goals. So, before diving into specific products, take some time to reflect on your driving habits and how you plan to use your truck. This will ensure that your turbo upgrade is a worthwhile investment.
Preparing Your Cummins for a Turbo Upgrade
Before you slap on a new shiny turbo, it’s important to make sure the rest of your Cummins is up to the task. A turbo upgrade often reveals weaknesses in other components, so proactive preparation is key to preventing headaches down the road. Imagine building a house – you wouldn’t start putting up the roof before ensuring the foundation is solid, right?
First and foremost, assess the condition of your injectors. Are they spraying cleanly and delivering the correct amount of fuel? Worn or clogged injectors can lead to poor combustion and reduced performance, negating the benefits of a new turbo. Think of injectors like tiny nozzles; if they’re clogged or leaking, they can’t efficiently deliver fuel to the engine.
Next, take a look at your fuel system as a whole. Upgrading your turbo often means demanding more fuel, so you might need a higher-flowing lift pump or even upgraded fuel lines. A weak fuel system can starve your engine of fuel, leading to decreased power and potential damage. This is especially critical if you’re chasing significant horsepower gains.
Finally, consider the health of your transmission. More power means more stress on the transmission, so make sure it’s in good working order. A rebuilt or upgraded transmission might be necessary to handle the increased torque. Imagine a tow truck pulling a heavier load than it was designed for – eventually, something’s going to break down. Preparing your Cummins properly will prevent it from being your transmission.
Installation Tips and Considerations
Installing a new turbo on your 5.9 Cummins can be a rewarding DIY project, but it’s crucial to approach it with care and precision. This isn’t like changing your oil; you’re dealing with complex engine components, so attention to detail is paramount. Think of it like building a model airplane – if you rush and skip steps, the final result might not fly so well.
First, always consult the manufacturer’s instructions thoroughly before starting the installation process. Each turbo is designed differently, and following the specific guidelines will ensure proper fitment and performance. This isn’t the time to wing it – taking shortcuts can lead to leaks, poor performance, or even engine damage. Think of them like the secret recipe to your favorite family dish.
Second, pay close attention to the proper torque specifications for all bolts and fittings. Over-tightening can strip threads, while under-tightening can lead to leaks. A torque wrench is your best friend in this situation – it ensures that everything is tightened to the correct level. Imagine trying to assemble furniture without the right tools.
Finally, remember to prime the turbo with oil before starting the engine for the first time. This ensures that the bearings are properly lubricated, preventing potential damage during initial startup. This is especially important for ball-bearing turbos, which are more sensitive to oil starvation. Think of it as giving your car a drink before embarking on a long drive. Taking these precautions will increase the lifespan of your turbo.
Maintaining Your Turbo Upgrade
You’ve invested in a shiny new turbocharger, and now it’s up to you to keep it running strong for years to come. Proper maintenance is key to maximizing its lifespan and performance. Think of it like buying a new car – regular servicing will ensure it stays in top condition.
One of the most important aspects of turbo maintenance is using high-quality oil and changing it regularly. Fresh, clean oil is essential for lubricating the turbo’s bearings and preventing wear and tear. Follow the manufacturer’s recommendations for oil type and change intervals. It’s the lifeblood of your engine.
Another important consideration is monitoring your EGTs. Excessive EGTs can damage the turbo and other engine components. A pyrometer gauge is a valuable tool for keeping an eye on these temperatures. If you consistently see high EGTs, you may need to adjust your fueling or consider a larger intercooler. They’re like the thermometer for your engine.
Finally, avoid sudden and extreme changes in engine load or RPM. Abruptly slamming on the throttle or shutting the engine off after a hard run can put excessive stress on the turbo. Let the engine idle for a few minutes after towing or aggressive driving to allow the turbo to cool down gradually. Treat it with respect, and it will reward you with years of reliable performance. Imagine you ran a marathon; you would want to cool down gradually before sitting down. This prevents sore muscles and promotes recovery.
Buying Guide:
Best Turbo Upgrades For 5.9 Cummins
Alright, Cummins enthusiast! You’re looking to give your 5.9 that extra oomph, huh? Diving into the world of turbo upgrades can feel like navigating a maze, especially with all the options and technical jargon thrown around. But don’t sweat it! This guide is designed to be your friendly co-pilot, helping you make informed decisions so you can find the best turbo upgrades for 5.9 Cummins and unleash the true potential of your rig. We’ll break down the key factors, speak in plain English, and steer you clear of any common pitfalls. Let’s get started!
1. Your Power Goals: What are You Really After?
First things first, you need to figure out what you actually want your 5.9 Cummins to do. Are you looking for a slight bump in horsepower for towing, or are you chasing serious competition-level numbers? A realistic assessment of your power goals is crucial because it directly impacts the size and type of turbo you’ll need. Overestimate, and you might end up with a laggy, difficult-to-drive setup. Underestimate, and you’ll be kicking yourself when you’re still wanting more.
Think of it like ordering a pizza. If you’re just snacking with a friend, a small pie is perfect. But if you’re feeding a whole party, you’ll need something much bigger. Turbochargers are the same – size matters. A smaller, more responsive turbo is great for daily driving and moderate towing, while a larger turbo will provide the big power gains you need for sled pulling or drag racing. Be honest with yourself about how you plan to use your truck, and you’ll be much happier with the end result.
2. Your Budget: How Much Are You Willing to Invest?
Let’s be real, turbo upgrades aren’t cheap. The best turbo upgrades for 5.9 Cummins can range from a few hundred dollars for a basic replacement to several thousand for a complete performance setup. It’s essential to set a realistic budget before you even start looking. This will help you narrow down your options and avoid getting caught up in features you don’t actually need. Remember to factor in not just the turbo itself, but also supporting modifications.
Think about it like this: buying a fancy new grill is great, but if you don’t have propane or charcoal, you’re not cooking anything. Similarly, a bigger turbo might require larger injectors, a better fuel pump, upgraded transmission components, and custom tuning to truly perform its best. Don’t forget to factor in the cost of installation, whether you’re doing it yourself or hiring a professional. A well-thought-out budget will prevent you from getting halfway through the project and realizing you’re short on funds.
3. Turbocharger Type: Single vs. Compound vs. VGT
The world of turbochargers is filled with acronyms and technical terms, but understanding the basic types is key to finding the best turbo upgrades for 5.9 Cummins. The main categories are single turbos, compound turbos (also known as twins), and Variable Geometry Turbos (VGTs). Each type offers different performance characteristics and has its own set of pros and cons.
A single turbo is the simplest and most common option, offering a good balance of performance and cost. Compound turbos use two turbos in series, a smaller one for quick spool-up and a larger one for high-end power. This is a popular choice for those chasing serious horsepower. VGTs, on the other hand, use adjustable vanes to optimize airflow at different engine speeds, offering good responsiveness and a wide powerband. The best choice for you will depend on your power goals, budget, and how you use your truck.
4. Turbine Housing Size and A/R Ratio: Understanding the Numbers
These numbers can seem confusing, but they’re crucial for understanding how a turbo will perform. The turbine housing size dictates how much exhaust flow is needed to spin the turbine wheel, while the A/R ratio (Area/Radius) describes the size and shape of the turbine housing scroll. Smaller A/R ratios result in faster spool-up but can limit top-end power, while larger A/R ratios offer more top-end power but can be laggy at lower RPMs.
Think of it like choosing gears on a bicycle. A smaller gear is easier to pedal from a standstill (faster spool-up), but you’ll quickly run out of speed. A larger gear is harder to get going (more lag) but allows you to reach higher speeds. The ideal turbine housing size and A/R ratio will depend on your engine’s characteristics, the size of the compressor wheel, and your desired driving style. Generally, a smaller A/R is preferred for towing, while a larger A/R is better for high-horsepower applications.
5. Compressor Wheel Size and Design: Matching Airflow to Your Engine
The compressor wheel is the heart of the turbo, responsible for compressing the air entering the engine. The size and design of the compressor wheel directly impact the amount of airflow it can deliver and the pressure it can generate. A larger compressor wheel can move more air, allowing for higher horsepower, but it also requires more energy to spin, potentially leading to more lag.
Imagine trying to blow up a balloon. A small balloon is easy to inflate quickly, but a large balloon takes more effort. Similarly, a smaller compressor wheel spools up faster but might not be able to deliver enough airflow for your desired power level. Compressor wheels come in different designs, such as extended tip and billet wheels, each offering different performance characteristics. Matching the compressor wheel to your engine’s needs is essential for achieving optimal performance and avoiding compressor surge.
6. Brand Reputation and Reliability: Choosing a Trustworthy Manufacturer
When it comes to turbo upgrades, you generally get what you pay for. Choosing a reputable brand with a proven track record is crucial for ensuring reliability and longevity. Cheaping out on a no-name turbo might seem tempting, but you could end up with a poorly made unit that fails prematurely or doesn’t perform as advertised. Stick with well-known brands that offer warranties and have a good reputation in the Cummins community.
Think of it like buying tools. You can buy a cheap, off-brand wrench set, but it’s likely to break or strip bolts when you really need it. Investing in a high-quality set from a reputable brand will save you headaches in the long run. Look for brands that have been around for a while, have positive customer reviews, and offer good customer support. Researching different brands and reading reviews is a worthwhile investment of your time.
7. Supporting Modifications: Ensuring a Balanced System
As mentioned earlier, upgrading your turbo is rarely a standalone modification. To truly unlock the potential of the best turbo upgrades for 5.9 Cummins, you’ll likely need to make other modifications to support the increased airflow and fuel demands. This might include upgrading your fuel injectors, fuel pump, intercooler, exhaust system, and transmission. A well-balanced system is key to achieving optimal performance and avoiding potential issues.
It’s like building a house. You can’t just put a huge roof on a weak foundation. You need to ensure that all the components are strong enough to support each other. Similarly, a bigger turbo requires more fuel and efficient cooling. Neglecting supporting modifications can lead to poor performance, excessive exhaust gas temperatures, and even engine damage. Talk to a knowledgeable diesel performance shop or do your research to determine what supporting mods are necessary for your specific setup and power goals.
Frequently Asked Questions
What size turbo is best for my 5.9 Cummins?
Choosing the right turbo size really depends on what you’re looking to get out of your truck. A smaller turbo will spool up quicker, giving you better low-end torque and responsiveness, which is great for daily driving and towing. However, it might run out of steam at higher RPMs if you’re chasing big horsepower numbers.
On the other hand, a larger turbo will provide more top-end power, but it will take longer to spool up, potentially causing some lag. So, consider your primary use case. If you’re mostly towing or daily driving, a smaller to mid-sized turbo is probably the way to go. If you’re building a dedicated performance truck, a larger turbo might be more suitable.
How much horsepower can I expect to gain from a turbo upgrade?
The horsepower gains you can expect really vary depending on the turbo you choose and the supporting modifications you have on your 5.9 Cummins. Simply slapping on a bigger turbo without addressing other areas like fuel delivery and airflow won’t unlock its full potential.
Generally speaking, you could see gains anywhere from 50 to over 200 horsepower with a turbo upgrade, depending on the turbo size and if you’re also upgrading your injectors, fuel pump, and intake. Keep in mind that proper tuning is crucial to ensure the turbo and engine are working in harmony and running safely.
Will a turbo upgrade affect my fuel economy?
A turbo upgrade can potentially affect your fuel economy, but not always in a negative way. A more efficient turbo can improve combustion and allow your engine to operate more efficiently under certain conditions, which could lead to slightly better mileage.
However, it’s also possible that you’ll see a decrease in fuel economy, especially if you’re heavy on the throttle enjoying the added power! The more aggressively you drive, the less efficient your engine will be. It really depends on your driving habits and the overall efficiency of your turbo setup.
Is it difficult to install a turbo upgrade myself?
Installing a turbo upgrade isn’t necessarily the easiest task, but it’s definitely doable for a mechanically inclined person with the right tools and some patience. It typically involves removing the old turbo, installing the new one, and connecting all the necessary lines and components.
However, it’s important to have a solid understanding of your engine and the turbo system before diving in. If you’re not comfortable working on your engine or you’re unsure about any part of the process, it’s always best to consult with a professional mechanic to avoid any potential issues.
Do I need to upgrade my injectors or fuel pump when upgrading my turbo?
Whether you need to upgrade your injectors and fuel pump really depends on the size of the turbo you’re installing and the horsepower goals you have in mind. For smaller turbo upgrades that aim for moderate horsepower gains, you might be able to get away with your stock fuel system, at least initially.
However, if you’re planning on a larger turbo that can deliver significantly more power, your stock fuel system will likely become a bottleneck. Upgrading your injectors and fuel pump will ensure that your engine gets enough fuel to support the increased airflow from the turbo, preventing lean conditions and potential engine damage.
What are the signs of a failing turbo?
There are a few telltale signs that your turbo might be on its way out. One common sign is a loss of power or boost pressure. You might notice that your truck feels sluggish or that it’s not accelerating as quickly as it used to.
Another sign is excessive smoke coming from the exhaust, especially blue or black smoke. You might also hear unusual noises, such as a high-pitched whine or grinding sound, coming from the turbo area. If you notice any of these symptoms, it’s a good idea to have your turbo inspected by a professional to prevent further damage.
How much does a turbo upgrade typically cost?
The cost of a turbo upgrade can vary widely depending on several factors, including the brand, size, and type of turbo you choose, as well as any additional components you might need, like installation kits or supporting modifications.
You can typically expect to spend anywhere from a few hundred dollars for a basic upgrade to several thousand dollars for a high-performance turbo kit with all the necessary components. It’s always a good idea to get quotes from multiple vendors and factor in the cost of installation if you’re not planning on doing it yourself.
Verdict
Choosing the right turbo for your 5.9 Cummins can feel like navigating a maze, but hopefully, this guide has shed some light on the path forward. Remember, every engine is unique, and what works best for one truck might not be ideal for another. Take your time, consider your goals, and don’t be afraid to dive deeper into the specifics of each option. Whether you’re chasing horsepower records or simply looking for a more responsive daily driver, the best turbo upgrades for 5.9 Cummins are out there, waiting to unlock your engine’s full potential.
Now, it’s your turn to take the reins and transform your Cummins into the beast you’ve always envisioned. The power is literally at your fingertips! Don’t hesitate to reach out to professionals, ask questions, and do your due diligence. The satisfaction of unleashing that extra performance and hearing that turbo sing is an experience you won’t soon forget. Go ahead, make that upgrade, and experience the thrill of a truly optimized 5.9 Cummins.