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SKU #: BD-1045172 MPN #: 1045172

BD Iron Horn Series S363SXE/76 .91AR Turbo Kit 03-07 Ram 5.9L Cummins

$2,168.95
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Description
While there are a ton of options out there to replace and upgrade the stock turbo on your 5.9L Dodge Ram Cummins, few offer the ease of installation coupled with superior performance delivered by the Iron Horn Series by BD-Power. All together this turbo kit will increase flow, improve efficiency, and stand up to some of your toughest challenges while also being easy and straightforward to install. If you are looking for an easy economical turbo upgrade, or, replace your tired turbo and aging exhaust manifold, then BD's Iron Horn series for your 3rd generation 5.9L Cummins offers a clean, drop-in installation. Featuring BorgWarner SX-E cartridges and 2-piece pulse exhaust manifold, BD's Iron Horn turbocharger kits are engineered to give optimal performance while reducing EGT's and high drive pressures. While you may or may not be going for racing, pulling, or drag the SX-E turbo was designed for SERIOUS POWER and supports that 950+ horsepower that your craving. In order to aid in simplicity, the high performance manifold is EGR compatible and retains the stock downpipe and intake instead of the "hot air" intakes or 2nd gen conversions. IMPORTANT FITMENT NOTE: 2003-2004 model years will require a 2004.5-2007 style 4" exhaust downpipe due to the 2003-2004 reducing in size to a 3" at the factory turbo.

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While there are a ton of options out there to replace and upgrade the stock turbo on your 5.9L Dodge Ram Cummins, few offer the ease of installation coupled with superior performance delivered by the Iron Horn Series by BD-Power. All together this turbo kit will increase flow, improve efficiency, and stand up to some of your toughest challenges while also being easy and straightforward to install.

If you are looking for an easy economical turbo upgrade, or, replace your tired turbo and aging exhaust manifold, then BD's Iron Horn series for your 3rd generation 5.9L Cummins offers a clean, drop-in installation. Featuring BorgWarner SX-E cartridges and 2-piece pulse exhaust manifold, BD's Iron Horn turbocharger kits are engineered to give optimal performance while reducing EGT's and high drive pressures. While you may or may not be going for racing, pulling, or drag the SX-E turbo was designed for SERIOUS POWER and supports that 950+ horsepower that your craving. In order to aid in simplicity, the high performance manifold is EGR compatible and retains the stock downpipe and intake instead of the "hot air" intakes or 2nd gen conversions.

IMPORTANT FITMENT NOTE: 2003-2004 model years will require a 2004.5-2007 style 4" exhaust downpipe due to the 2003-2004 reducing in size to a 3" at the factory turbo.

NOT LEGAL FOR SALE OR USE IN CALIFORNIA
Manuals and Guides
Vehicle Fitment
2003-2007 Ram 5.9L Cummins
WARNING: Cancer & Reproductive Harm - P65Warnings.ca.gov
FEATURES & BENEFITS:
  • BD Single 300 series SX-E Borg Warner turbos kits that replace your OEM turbo, providing enough air for more power, response and reliability
  • Utilizes stock air intake and downpipe*, no need to change either for what you are currently running
  • Turbo utilizes high flow T4 turbine housing
  • The SX-E turbo was designed for performance with a 360 thrust bearing and enhanced compressor wheel and housing
  • The high strength FMW Forged Milled Wheels are lighter and stronger and withstand higher wheel speeds
  • Kit comes with BD's Performance Plus T4 5.9L exhaust manifold and gaskets
  • No extra piping required, it drops in place for an easy, clean installation
  • Comp Wheel: 63mm/ 2.48in
  • Turbine Wheel: 76mm / 2.99in
  • A/R Ratio:  .91
  • Flow:  79 Lb/min
  • Approximate rated 550hp (depending on truck configuration)
IMPORTANT NOTES:
  • Not for sale on licensed California vehicles
  • Air intake kits may need alteration other than K&N kit and OEM intake system
  • Custom tuning is necessary for alterations to the VGT system when you install this kit
  • 2003-2004 model years will require 2004.5-2007 style downpipe and clamp, both available options from above.
About BD-Power

BD Diesel is known as one of the originators of diesel performance because theyve been there since the very beginning. Its by no coincidence that theyve been in the industry since 1972 where theyve seen competition come and go over the years. You could consider them a front to back organization in which they design and manufacture products ranging from Super B Turbo Kits and performance injectors for your Cummins to heavy duty transmissions, torque converters, and other transmission components for your Duramax to Positive Air Shutdowns and exhaust brakes for your Powerstroke and everything in between. Quite literally, there are VERY few components that BD does not build for nearly every light duty diesel application.

BD DIESEL PERFORMANCE

Originally founded in 1972 as Valley Fuel Injection that specialized in fuel injection rebuilding and calibrating, BD Diesel gained the most notoriety beginning in 1989 with the release of their first exhaust brake designed for Ram trucks with the acclaimed 12 Valve Cummins engine. BD would later rename Valley Fuel Injection to BD Diesel Truck Service and Performance Center that operates as an extension to BD Diesel Performance. Today, they operate out of a 65,000 square foot facility in Abbotsford, British Columbia and employ over 100 highly skilled individuals. They are constantly pushing the envelope with forward thinking products that not only fill voids in the marketplace, but also take existing products and push them to the next level.

BD DIESEL TRANSMISSION UPGRADES

Transmissions have a singular but ambitious challenge - to transfer all the torque from the diesel engine to the drive wheels. This must be accomplished while maintaining shift quality and minimizing NVH (Noise, Vibration, and Harshness). With stock or OE configurations, this capacity challenge is somewhat less than extraordinary. Comparatively, a high output diesel that develops 2-4 times the original engine torque and keeping stellar driving characteristics at this power level becomes a new feat. Utilizing the latest technology in CAD and FEA simulation, BD can predict and eliminate failures before they happen. The dedicated team of BDs Transmission and Torque Convertor Department are true experts in the development and analysis of the diesel transmission.

BD EXHAUST BRAKES

BD built its reputation on exhaust brakes starting in the early 90's with many casting designs for both engine and remote mount air actuated systems. Rugged cast-iron bodies with an offset stainless steel butterfly build peak efficiency quickly.

BD TURBO UPGRADES

The turbocharger industry is a special industry for BD and remains a key technological asset. When looking at BDs experienced staff, the majority of their key staff members have been developed in or around this technology. BD focuses on the customer's needs, whether it is fast turnaround, state of the art compressor wheels or turbine wheels, they look to deliver on the highest expectations. You can be assured that a BD turbocharger has been hand crafted to the greatest standards. Using precision lathes, milling equipment, honing machines, and inspection CMMs your turbocharger is continuously graded to exceed the OEMs specifications.

BD FUELING UPGRADES

Owing to its heritage as a diesel fuel systems specialist, BD Diesel Truck Service & Performance Center is a factory-certified Bosch, Stanadyne, Delphi and Zexel calibration and repair lab. They are one of a select few injection shops in North America to have Bosch Common Rail parts and an overhaul and testing franchise. BD Diesel rebuilds most all mechanical and electronically-controlled fuel pumps and injectors for diesel engine applications.

BD ELECTRONICS

Throughout the automotive industry, electronic technology has become an integral part of the OEM solution. Whether it is safety, performance, or driving improvements, BD Diesel Performance has developed a strong electronic department to focus strictly on this technology. By focusing on the core needs of the customer, they engineer out the possible product failures and maximize key features to deliver a top to bottom solution. Utilizing state of the art manufacturing equipment, BD maximizes value and minimizes time consuming tasks that inflate costs. Vehicle electronic technology will remain a key technology at BD Diesel Performance.

Overall rating: 4.0 / 5 from 1 reviews.

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Reviews

Great kit but not without its issues.

"I've had this turbo and exhaust in for exactly one tank of fuel, and I am impressed! Combined with the S&B CAI I installed last month, it is as though she was breathing through a straw and is finally taking a fuller breath. Everything just runs smoother and is more responsive. There's less smoke as though less unburnt fuel is being dumped out of the tail pipe. It feels like the truck isn't having to work as hard. Fuel mileage increased about 25 miles to this tank, but we'll see over the long haul. So far I'm very pleased with its performance. That said, I assumed it would be "drop-in" ready, but there were fitment issues. The most frustrating of which is that the turbo is moved forward almost two inches from stock. I had to force the exhaust forward using ratchet straps, so now that old downpipe is under tension. I'm hoping it doesn't crack while I'm waiting to get a new exhaust. On that note, you guys don't have much of a selection of 4" turbo back exhaust kits or downpipes for 2004. 5-2007 CTD. Im having to go elsewhere for it. Also, the aforementioned brand-new intake was subsequently pushed forward about 2" in the air box, and the box no longer seals against the intake tube allowing engine bay air to be taken up. If I had known, I may have held off and gone with a different CAI. Great kit but not without its headaches."

Sean M. (4/5)

Q&A

Would by BD exhaust break elbow contact to the back of this turbo.
The BD exhaust brake would not be able to mount to the back of the BD Iron horn turbos.
Would this kit require larger injectors on a 2006 CR Cummins?
You could run the factory injectors with this turbo set up. It would be recommended to possibly look into some 50HP injectors if you want to push the turbo to it's full capability. Custom Tuning is recommended as well. -Mark
On 04.5 truck since I wouldn’t be using the factory wastegate electronic solenoid is this kit going to throw codes with that circuit being unplugged? Would a smarty tuner fix that?
Going with one of these Iron Horn series kits you will need to source a Boost Fooler such as the BD-1515936. The S03 Recalculates boost numbers to prevent defueling. With the wastegate being removed a boost fooler will need to be present to give a false signal of the wastegate still being there. -Mark
Can this kit be bought and drove on then eventually added to, for a compound set up?
There is not going to be a bolt on compound addition that we would have. But you could use the turbo in a compound setup, the manifold maybe depending on how it is setup. DppSands