A turbo upgrade kit adds a larger or modified turbocharger to your 6.7 Cummins diesel engine
A 6.7 Cummins turbo upgrade kit replaces your factory turbocharger with a bigger one, a different design, or one modified for higher boost pressure. The factory turbo on a 6.7 Cummins (used in Dodge Ram trucks from 2007 onward) is built to balance fuel economy, emissions, and durability. An upgraded turbo sacrifices some of that balance to push more air into the engine, which lets you burn more fuel and make more power.
The kit typically includes the new turbocharger itself, new intake and exhaust piping sized for the larger unit, gaskets, bolts, and sometimes a new intercooler. Some kits also include a tuning file you load into the engine computer to adjust fuel injection and boost targets. Installation usually takes a shop between 8 and 16 hours, depending on which kit and which truck model you have.
Owners pursue turbo upgrades for three main reasons: to increase horsepower and torque for towing or hauling, to improve throttle response and acceleration, or to support other engine modifications they've already made. A turbo upgrade alone typically adds 75 to 150 horsepower and 150 to 250 pound-feet of torque, though the actual gain depends on the kit, your tune, and what fuel you run.
Key Takeaways
- Turbo upgrade kits replace the factory turbocharger with a larger or modified unit and include new piping, gaskets, and often a tuning file for the engine computer.
- A turbo upgrade typically adds 75 to 150 horsepower and 150 to 250 pound-feet of torque, but gains vary based on the specific kit, tune, and fuel octane.
- Installation requires 8 to 16 hours at a diesel shop and costs between $2,000 and $5,000 for parts and labor, depending on the kit brand and your location.
- Upgrading the turbo puts stress on the fuel system, transmission, and engine internals, so many owners pair it with injector upgrades, transmission tuning, or engine reinforcement.
- Warranty coverage on your truck engine may be voided by a turbo upgrade, and some kits can affect emissions compliance or fuel economy.
Popular turbo upgrade kit brands and what they target
The most common 6.7 Cummins turbo upgrade kits come from Fleece Performance, Calibrated Power Solutions (CPS), Wicked Diesel, and BD Diesel. Each brand offers multiple kits aimed at different power levels and budgets. Fleece's Street Series kits, for example, are designed for daily drivers who want more power without extreme heat or noise. Fleece's Competition Series targets owners building trucks for pulling contests or dyno events.
CPS kits often pair a larger turbo with a custom intake manifold and are popular among owners who want a complete bolt-on solution. Wicked Diesel focuses on high-flow designs that reduce turbo lag. BD Diesel kits tend to be pricier but include extensive engineering and support for very high power levels.
Kit prices range from roughly $2,000 to $4,500 for the turbo, piping, and hardware alone. Labor at a diesel shop typically runs $1,500 to $2,500, so a complete installation usually costs between $3,500 and $7,000. Some shops offer package deals if you buy the kit through them.
What happens to your engine when you upgrade the turbo
A larger turbo spins faster and pushes more air into the cylinders at higher pressure. This means the engine can inject more fuel per combustion cycle, which creates more power. But it also creates more heat, more stress on the pistons and connecting rods, and higher exhaust temperatures.
The factory fuel injectors may not spray enough fuel to match the extra air, so many owners upgrade to larger injectors at the same time. The transmission feels the extra torque too — if you tow or accelerate hard, an upgraded turbo can shorten the life of a stock transmission or cause it to slip. Some owners add transmission tuning or a transmission cooler to handle the load.
Exhaust gas temperatures (EGT) rise noticeably with a turbo upgrade. Factory gauges may not display EGT, so owners often install an aftermarket EGT gauge to monitor heat. Running too hot for too long can damage the turbo itself, the exhaust manifold, and the DPF (diesel particulate filter). This is why many turbo kits come with tuning that limits boost at lower speeds or in certain driving conditions.
Warranty, emissions, and fuel economy trade-offs
Installing a turbo upgrade kit will void the factory engine warranty on your truck. Dodge and Cummins will not cover engine damage if they find evidence of a turbo modification. Some owners carry aftermarket engine warranty plans from companies like Powertrain Protection or Cummins Certified Remanufactured programs, though these typically exclude modified engines unless you disclose the work upfront.
Emissions compliance is another consideration. A turbo upgrade changes the engine's air and fuel ratio, which affects nitrogen oxide (NOx) and particulate matter output. If your truck is registered in a state with emissions testing, a modified turbo may cause it to fail inspection. Federal law prohibits removing or disabling the DPF, so you cannot straightforward delete emissions equipment to compensate. Some kits are designed to work within emissions limits, but this is not may provide.
Fuel economy typically drops 1 to 3 miles per gallon after a turbo upgrade, especially if you drive aggressively or tow frequently. The engine is now capable of burning more fuel, and most drivers use that capability. If you drive conservatively and avoid high boost, you may see a smaller loss.
Installation and what to expect at the shop
A turbo upgrade requires removing the factory turbocharger, which means disconnecting the intake manifold, exhaust manifold, coolant lines, oil supply and return lines, and the boost hose. The new turbo goes in with new gaskets and seals, and the larger piping is routed to fit your truck's engine bay. Some kits require minor modifications to brackets or hoses to clear other components.
After the turbo is installed, the shop will connect a laptop to your truck's engine computer and load the tuning file that came with the kit. This file adjusts fuel injection timing, quantity, and boost targets. The shop may also perform a test drive to check for boost leaks, unusual noises, or warning lights.
Most shops will not install a turbo kit without also checking your fuel injectors, fuel pump, and intercooler condition. If any of these are worn, they recommend replacing them at the same time. A full turbo upgrade with injectors and intercooler can push the total cost to $5,000 to $8,000.
Pairing a turbo upgrade with other modifications
A turbo upgrade works best when combined with supporting modifications. Fuel injector upgrades (usually 100 to 150 percent over stock) allow the engine to use the extra air the turbo provides. Intercooler upgrades cool the compressed air more efficiently, which increases air density and power. Intake manifold modifications improve air flow into the turbo. Exhaust system upgrades (larger downpipe, cat-back exhaust) reduce backpressure and let the turbo spool faster.
If you tow or drive aggressively, a transmission tune or transmission cooler is nearly essential. A stock transmission can handle the extra torque for a while, but repeated hard acceleration or heavy towing will wear it out faster. Transmission tuning adjusts shift points and torque converter lockup to distribute the load more evenly.
Some owners also upgrade the engine oil cooler, add a secondary fuel filter, or install a boost controller to fine-tune how much pressure the turbo produces. These are optional but reduce the risk of overheating or fuel starvation under extreme conditions.
Common problems and how to avoid them
The most common issue after a turbo upgrade is a boost leak — a small crack or loose connection in the intake piping that lets pressurized air escape. This reduces power and can trigger a check engine light. A good shop pressure-tests all new piping before you leave, so this should be caught during installation.
Turbo surge or compressor surge happens when the turbo spools too fast and the engine cannot burn the fuel quickly enough, causing a backfire or popping sound. This is usually a tuning issue and can be fixed by adjusting the boost curve in the engine computer. Some kits include a blow-off valve to prevent this.
Overheating is another risk, especially if you tow in hot weather or drive at highway speeds with high boost. Monitoring EGT with a gauge and backing off the throttle when temperatures climb above 1,200 degrees Fahrenheit will protect your turbo and engine. Many owners install a pyrometer (EGT gauge) as soon as they upgrade the turbo.
Premature turbo failure can occur if the engine runs out of oil, if the turbo bearings are starved of coolant, or if the turbo is pushed beyond its design limits. Using quality synthetic diesel oil, keeping the cooling system clean, and respecting the boost limits set by your tune will extend turbo life.
Frequently Asked Questions
Will a turbo upgrade make my truck faster in a straight line?
Yes. A turbo upgrade typically adds 75 to 150 horsepower and 150 to 250 pound-feet of torque, which improves acceleration noticeably. The exact gain depends on the kit, your tune, and fuel octane. You will feel the difference most in the 2,000 to 4,000 RPM range, where the turbo produces peak boost.
Can I install a turbo upgrade myself?
It is possible if you have diesel engine experience and the right tools, but most owners take their truck to a shop. The work requires disconnecting and reconnecting oil, coolant, and fuel lines with precision, and the tuning file must be loaded correctly. A mistake can cause oil leaks, boost leaks, or engine damage. Shop installation is safer and usually comes with a warranty on the work.
What fuel should I run after a turbo upgrade?
Most turbo kits are tuned for standard diesel (number 2 diesel). Some kits include a second tune file for winter or summer conditions. Using quality fuel from major stations reduces the risk of fuel contamination or water in the tank, which can damage upgraded injectors. Avoid blending biodiesel unless your kit is specifically rated for it.
How long does a turbo upgrade last?
A quality turbo upgrade kit can last 100,000 to 150,000 miles if maintained properly. This means regular oil changes, keeping the cooling system clean, and not pushing the engine beyond its tune limits. Turbos that are run too hot or too hard may fail sooner. Replacing a turbo after failure costs $1,500 to $2,500 in parts and labor.
Will a turbo upgrade affect my truck's resale value?
Most buyers of used diesel trucks view modifications as a risk rather than an upgrade, so resale value typically does not increase. Some enthusiast buyers may pay more for a well-documented, professionally installed kit, but this is not may provide. Disclose any modifications to potential buyers, as hidden modifications can create legal liability if the truck fails inspection or breaks down.