A turbo upgrade kit increases boost pressure and airflow to your 6.7L diesel engine

A turbo upgrade kit for the 6.7 Powerstroke (the diesel engine in Ford Super Duty trucks from 2011 onward) replaces or modifies your factory turbocharger to push more air into the engine at higher pressure. The factory turbo is designed to balance power, fuel economy, and longevity across a wide range of driving conditions. An upgrade kit trades some of that balance for more horsepower and torque — typically adding 50 to 150 horsepower depending on the kit and whether you pair it with other modifications like a tuner or fuel system changes.

The upgrade works by using a larger compressor wheel, different turbine housing, or both, so the turbo spins faster and compresses more air. More air means more fuel can burn in each cylinder, creating more power. The tradeoff is higher exhaust temperatures, more stress on engine components, and potentially shorter intervals between maintenance. Whether a kit makes sense for your truck depends on what you use it for, how long you plan to keep it, and whether you are comfortable with the maintenance demands.

Key Takeaways

  • Turbo upgrade kits add 50 to 150 horsepower by increasing boost pressure, but they also raise exhaust temperatures and engine stress.
  • Installation typically requires removing the factory turbo, intake manifold, and exhaust components — a job that takes 8 to 16 hours and usually costs $1,500 to $3,000 in labor if you do not do it yourself.
  • Pairing a turbo kit with a tuner, fuel system upgrade, or both is common and often necessary to see the full power gain and avoid engine strain.
  • Upgraded turbos run hotter and may shorten the life of your engine oil, coolant, and turbo itself if you do not follow a stricter maintenance schedule.
  • A turbo upgrade can void your factory warranty and may affect your truck's resale value depending on the buyer's preferences.

How turbo upgrade kits differ from the factory turbo

The factory 6.7 Powerstroke turbo is a Garrett unit designed to provide good power across the RPM range while keeping the engine within safe operating limits for a truck that might tow, idle in traffic, or sit parked for months. It balances boost pressure (typically 20 to 25 PSI at full load) with durability and emissions compliance.

An upgrade kit usually replaces the turbo with a larger or differently tuned unit — common brands include Garrett, BorgWarner, and Holset — that can produce 28 to 35+ PSI of boost. Some kits use a twin-turbo setup instead of a single larger turbo, which can spool faster and provide boost at lower RPMs. The higher boost pressure forces more air into the cylinders, which allows you to burn more fuel and create more power. The downside is that higher boost also means higher exhaust gas temperatures (EGT), which stresses the turbo, exhaust manifold, pistons, and other components.

Installation, labor, and what you need to remove

Installing a turbo upgrade kit is not a bolt-on job. The factory turbo is mounted to the exhaust manifold and connected to the intake, intercooler, and exhaust piping. To swap it out, a technician must remove the intake manifold, exhaust manifold, turbo mounting hardware, all the piping, and sometimes the intercooler. On a 6.7 Powerstroke, this typically takes 8 to 16 hours depending on the kit, the technician's experience, and whether other work is done at the same time.

Labor costs vary by region and shop, but expect $1,500 to $3,000 for installation alone. Some shops bundle the turbo kit, installation, and a tuner into a package deal. If you have the skills and tools, you can do the work yourself and save the labor cost, but you will need a lift, a good set of sockets and wrenches, gasket scrapers, new gaskets and seals, and time. Many people choose to have a diesel shop handle it because the work involves critical seals and tolerances, and a mistake can lead to boost leaks or oil leaks that damage the engine.

Pairing a turbo kit with tuning and fuel system upgrades

A turbo upgrade kit alone will add power, but most owners pair it with a tuner — a device that reprograms the engine control module (ECM) to adjust fuel injection timing, quantity, and boost targets. A tuner lets you take full advantage of the upgraded turbo's ability to push more air, and it can also adjust shift points, fan operation, and other parameters. Popular tuners for the 6.7 Powerstroke include the EFILive, Smarty, and Bully Dog, each with different features and price points ranging from $400 to $800.

Many owners also upgrade the fuel system — injectors, fuel pump, or both — to supply the extra fuel needed to match the extra air. Without adequate fuel, you will not see the full power gain, and the engine may run lean, which raises EGT and risks damage. A fuel system upgrade can cost $500 to $1,500 depending on what you change. The combination of a turbo kit, tuner, and fuel system upgrade can add 100 to 200+ horsepower, but it also requires more frequent oil changes, cooler running temperatures, and careful monitoring of EGT.

Maintenance and engine stress from higher boost

Higher boost pressure and exhaust temperatures put more stress on your engine, which means maintenance intervals may need to tighten. Engine oil breaks down faster under higher heat, so many owners switch to a heavier-duty synthetic oil and change it every 5,000 miles instead of the factory 10,000-mile interval. Coolant also works harder, so flushing it more often is common. The turbo itself runs hotter, which can shorten its lifespan — a factory turbo might last 150,000 to 200,000 miles, while an upgraded turbo under heavy use might last 100,000 to 150,000 miles.

Exhaust gas temperature (EGT) is the key metric to watch. Factory limits are typically 1,200 to 1,400 degrees Fahrenheit. With an upgrade kit and tuner, EGT can climb to 1,600 degrees or higher, especially under load or towing. Sustained high EGT damages the turbo, exhaust manifold, and pistons. Most tuners include an EGT gauge or can display it on a handheld monitor so you can see when you are pushing the engine hard and back off if needed.

Warranty, resale value, and legal considerations

Installing a turbo upgrade kit will void your factory powertrain warranty. Ford will not cover engine, transmission, or turbo repairs once modifications are detected. If something fails — a piston, a bearing, the turbo itself — you pay for the repair out of pocket. Some aftermarket warranty companies offer coverage for modified diesel engines, but the cost and coverage limits vary.

Resale value is mixed. Some buyers view a turbo kit as a desirable upgrade and will pay more for a truck with proven modifications and documentation. Others see it as a red flag that the engine has been stressed and may have hidden damage. If you plan to sell the truck, be upfront about the modifications and keep records of all maintenance and tuning changes. In some states, a modified diesel may also face emissions testing issues, so check your local regulations before committing to the upgrade.

Alternatives if you want more power without a full turbo swap

If a turbo kit feels like too much commitment, you have other options. A tuner alone can add 30 to 60 horsepower by optimizing fuel injection and boost targets without changing the turbo itself. This is the cheapest route — usually $400 to $800 — and it does not require any mechanical work. The downside is that you are still limited by the factory turbo's size, so the power gain plateaus.

A cold air intake or exhaust system upgrade can add 10 to 20 horsepower each by improving airflow, and they are easier to install than a turbo kit. These are often done alongside a tuner to maximize the effect. If you want moderate power gains and plan to keep the truck stock-looking, this combination is a practical middle ground.

Frequently Asked Questions

Will a turbo upgrade kit void my warranty?

Yes. Ford's factory warranty covers the powertrain (engine, transmission, turbo) for three years or 36,000 miles. Any modification to the fuel system, turbo, or engine control module will void that coverage. You can purchase aftermarket warranty coverage for modified engines, but it is typically more expensive and has limits on what it covers.

How much horsepower will I actually gain?

A turbo kit alone typically adds 50 to 100 horsepower. Paired with a tuner, you might see 80 to 150 horsepower. Add a fuel system upgrade and you could reach 150 to 200+ horsepower. The exact number depends on the specific kit, your tuner settings, and how hard you push the engine. Dyno testing at a diesel shop will show you the real number for your truck.

Can I install a turbo kit myself?

Yes, if you have mechanical skills, a lift, and the right tools. The job takes 8 to 16 hours and involves removing the intake manifold, exhaust manifold, and all turbo piping. Many people choose to have a diesel shop do it because mistakes with seals or tolerances can cause boost leaks or oil leaks. If you do it yourself, budget for new gaskets, seals, and possibly a new intercooler hose kit.

What is EGT and why does it matter?

EGT (exhaust gas temperature) is how hot the gases leaving the engine are. Factory limits are around 1,200 to 1,400 degrees Fahrenheit. With a turbo upgrade, EGT can climb to 1,600 degrees or higher, which damages the turbo and engine over time. Most tuners let you monitor EGT so you can avoid sustained high temperatures. Towing and heavy acceleration raise EGT the most.

Will a turbo upgrade affect my fuel economy?

Yes, usually negatively. A turbo kit and tuner are optimized for power, not efficiency. You will likely see 1 to 3 MPG lower fuel economy, especially if you drive aggressively or tow. If fuel economy is important to you, a tuner alone with conservative boost settings is a better choice than a full turbo upgrade.