Recipes for Horsepower | 2003-2004 Ram 5.9 Cummins

We get a lot of calls asking, "What do I need to do to my truck to attain a certain horsepower level?" If you've been wondering the same, below are various "recipes" of parts that are needed to reach certain power levels along with any companion parts that you'll need to ensure the overall drivability and integrity of your truck. For example, you could grab the highest setting on your programmer to make 500HP on a dyno run but for longevity sake, you would be better off with a set of 50HP Injectors and a lower setting on the tuner. Or we will recommend an upgraded lift (fuel) pump once you've reached a power level where we have found it to be necessary. We are going to mention a lot of specific products, and these are products that we prefer through our experience. There are, of course, many other options available that can get the job done, as well.

Bear in mind that even though Dodge says your truck is 305HP they are quoting flywheel horsepower, not rear wheel horsepower. On a dyno, the actual rear wheel horsepower for these trucks is about 250HP. Please don't get sucked into the trap of adding all of the manufacturer stated horsepower gains for the individual products together to estimate your horsepower. This will only lead to disappointment! There is typically a substantial amount of overlap when combining products, but this is a necessary evil.


300 Horsepower

• S&B Cold Air Intake
• 4" Turbo Back Exhaust
• BD Boost Fooler

Drivetrain Upgrades

• Automatic: non-necessary
• Manual: non-necessary

400 Horsepower

• Smarty Jr.
• S&B Cold Air Intake
• 4" Turbo Back Exhaust
• BD Boost Fooler
• Edge Insight CTS2

Drivetrain Upgrades

• Automatic: Minimum would be a BD Valve Body. Ideally you would add a BD Single Disc Torque Converter
• Manual: Valair HD Spring Hub single disc clutch.

500 Horsepower

• S&B Cold Air Intake
• 4" Turbo Back Exhaust
• BD Super B Killer SX-E S361 Turbo Kit
• BD Exhaust Manifold
• BD 60 HP Injector Set
• Smarty Touch Programmer
• BD Boost Fooler
• FASS Titanium Lift Pump
• Fleece CP3K Injection Pump
• BD Power Fuel Distribution Block
• D Power Common Rail Fuel Plug

Recommended Drivetrain Upgrades

• Automatic: BD Torque Single or Triple Disc Torque Converter and Valve Body
• Manual: Valair Kevlar/Ceramic Single Disc Clutch or Valair Spring Hub Dual Disc Clutch with organic facings.

600 Horsepower

• S&B Cold Air Intake
• Smarty Touch
• GDP Air Boss Intake Plenum
• Banks Techni-Cooler Intercooler
• 4" or 5" Turbo Back Exhaust
• BD Power Super B 600 SX-E S364.5 Turbo Kit
• BD Exhaust Manifold
• Fleece Performance PowerFlo 10mm CP3 Injection Pump
• FASS Titanium Lift Pump
• ARP Head Studs
• Dynomite Diesel 90HP Injector Set
• S&B Intake manifold
• BD Power Fuel Distribution Block
• BD Power Fuel Sump
• D Power Common Rail Fuel Plug

Recommended Drivetrain Upgrades:

• Automatic: BD Triple Disc Converter, BD Valve Body, Billet Input Shaft, Billet Output Shaft or full built race transmission
• Manual: Valair Spring Hub Dual Disc with full ceramic facings or kevlar/ceramic for the daily driver/heavy towing/drag racing. If you are planning on sled pulling on a regular basis you would want to step up to the Valair 13" Dual Disc with steel inserts rated to 800HP.

700 Horsepower

• S&B Cold Air Intake System
• HP Tuning Hardway Performance
• GDP Air Boss Intake Plenum
• Banks Techni-Cooler Intercooler
• 5" Turbo Back Exhaust
• BD Power Super B 700 SX-E S369 Turbo Kit
• BD Power 2-Piece Exhaust Manifold
• BD Power High Performance R900 12mm CP3 Injection Pump
• FASS Titanium Lift Pump
• ARP Head Studs
• Dynomite Diesel 90HP Injector Set
• S&B intake manifold
• Edge Insight CTS2
• BD Power Fuel Distribution Block
• D Power Common Rail Fuel Plug
• BD Power Fuel Sump

Recommended Drivetrain Upgrades

• Automatic: Full built race transmission with Triple Disc converter, billet input and output shafts
• Manual:Valair 13" Dual Disc with steel inserts rated to 800HP