Wehrli 04.5-07 Dodge 5.9L Cummins S400 Turbo 2nd Gen Swap Kit (No Turbo/Manifold) - Illus Blueberry

If you're looking to upgrade your 2003-2007 Dodge 5.9L Cummins with an S400-based turbocharger, this kit from Wehrli Custom Fabrication is designed to make that swap much more straightforward. It specifically allows you to mount an S400 turbo using a 2nd Gen style exhaust manifold, which is sold separately. This setup positions the manifold pointing upwards, simplifying the installation of your downpipe. The included downpipe connects directly to your existing exhaust system's V-band flange, similar to how the factory turbo setup did, meaning no cutting of your exhaust is required.

Wehrli builds each kit in-house, with experienced fabricators and welders ensuring that every component is carefully constructed and test-fitted on an engine to confirm proper fitment. The tubing is TIG welded for strong, clean joints, and the mating flanges are CNC machined. Where needed, these flanges include O-ring seals to create a boost-leak-free connection, which is crucial for maintaining consistent turbo performance. This kit comes with a one-piece 3-inch hot-side intercooler pipe, a 4-inch shorty downpipe that mates to the exhaust V-band, and the necessary oil feed and drain line assembly. It also includes silicone boots with stainless steel T-bolt clamps for secure connections.

The kit is finished with a durable custom powder coat in an Illusion Blueberry color, and it even comes with an Outerwear's pre-filter cover for the included 5-inch intake and dry air filter. While the turbo and exhaust manifold are not included, this kit provides all the other essential components to get your S400 turbo installed and running.