5.9 Cummins Compound Turbo Kit | 3rd Gen Twin Turbo System | 2003-2007 Dodge Ram
The Diesel Power Source® compound turbo kit is a complete twin turbo system for 2003-2007 Dodge Ram 2500 and 3500 trucks with the 5.9L common rail Cummins engine. This is a turn-key kit that includes both turbos (S300 high-pressure and S400 atmospheric), a 3-piece high-flow exhaust manifold, all charge piping, oil lines, air intake, and hardware needed for installation. From 400 RWHP up to 1,200+ HP with supporting modifications, these sequential turbo kits bolt directly to the 3rd gen Cummins factory exhaust with no cutting or fabrication required.
Available in thirteen turbo size configurations with optional Turbonator® VGT upgrade for exhaust braking and faster spool, and optional ball bearing upgrade for approximately 200 RPM quicker spool-up. Whether you are building a 2003 Cummins 5.9 for towing, a 2005 Dodge Cummins turbo setup for daily driving, a 2006 Ram 2500 turbo upgrade for sled pulling, or a 2007 5.9 Cummins turbo platform for racing, DPS has a compound kit sized for your goals.
Why the 3rd Gen 5.9 Common Rail Responds So Well to Compounds
The 2003-2007 5.9L Cummins is one of the most responsive diesel platforms for compound turbo systems. The common rail fuel injection system (23,000-26,000 PSI) provides precise electronic fuel control that responds extremely well to increased airflow, unlike the mechanical VP44 injection pump on the earlier 24V trucks. When you add a compound turbo system that delivers significantly more air at cooler temperatures, the common rail ECM can take advantage of every bit of it. This is why 3rd gen Cummins diesel trucks with compound turbos consistently produce dramatically lower EGTs - 250-450°F lower under hard load - than the same truck on a single turbo.
The 3rd gen platform also benefits from a stronger 48RE automatic transmission (compared to the 47RE in 2nd gen trucks) and improved engine internals that support higher cylinder pressures. Combined with the bolt-on fit of the DPS compound kit, the 2003-2007 5.9 Cummins is the ideal platform for a compound turbo upgrade.
How Compound Turbos Work on a 5.9 Cummins
A compound (twin turbo) system uses two turbochargers working in series as a sequential turbo setup. The smaller S300 high-pressure turbo spools first at low RPM, delivering the instant throttle response that 3rd gen Cummins diesel owners expect. As RPM and load increase, the larger S400 atmospheric turbo takes over the majority of the compression work, providing the sustained airflow needed for high-HP applications without the lag that large single turbos create.
The two turbos share the compression work, which means each operates within its most efficient range. The result is boost air that is over 100°F cooler than a single turbo at the same pressure, boost-to-drive pressure ratios approaching 1:1, and 250-450°F lower EGTs under load. This is why DPS compound kits are the preferred diesel performance choice for 3rd gen Cummins owners who tow heavy loads through mountain passes, where EGT control is critical.
For a detailed explanation, see: How Do Compound Turbos Work? | Compound Turbochargers Explained
Stage Selection Guide
| Stage | Configuration | HP Range (RWHP) | Best For |
|---|---|---|---|
| Stg 2.5 | S362/68 over S475 | 400-625 | Outstanding towing and daily driving. Fastest spool in the compound lineup. |
| Stg 3 | S362/68 over S480 | 425-650 | More top-end headroom with S480 atmospheric. Strong towing and street choice. |
| Stg 3.5 | S362/68 Ball Bearing over S475 | 375-625 | Quickest spool in the compound lineup. Same top-end as Stg 2.5 with faster response. |
| Stg 4 | S363/68 over S475 | 425-700 | Slightly more airflow than S362. Good balance of spool and output. |
| Stg 4B | S363/68 over S480 | 450-725 | S480 atmospheric adds top-end headroom with S363/68 small turbo. |
| Stg 4.5 | S363/68 Ball Bearing over S475 | 400-700 | Ball bearing version of Stg 4. Faster spool for towing and performance. |
| Stg 4.5B | S363/68 Ball Bearing over S480 | 425-725 | Ball bearing version of Stg 4B. More top-end flow with faster spool. |
| Stg 5 | S363/73 over S475 | 475-750 | Popular all-around compound. Larger turbine wheel for more top-end flow. |
| Stg 5.5 | S363/73 Ball Bearing over S475 | 450-750 | Ball bearing version of Stg 5. Same top-end with quicker spool-up. |
| Stg 6 | S363/73 over S480 | 500-800 | High HP builds with S480 top-end headroom. |
| Stg 6.5 | S363/73 Ball Bearing over S480 | 475-800 | Ball bearing version of Stg 6. Faster spool with the same top-end capability. |
| Stg 8 | S366/73 over S480 | 600-1,100 | Competition, sled pulling, racing. Most popular high-performance 5.9L compound. |
| Stg 8.5 | S366/73 Ball Bearing over S480 | 575-1,100 | Ball bearing version of Stg 8. Same top-end with approximately 200 RPM quicker spool. |
How to choose: For a 2003-2007 5.9 Cummins focused on towing and daily driving, Stage 2.5 through 5 covers most builds. For performance builds above 500 RWHP, Stage 5 and above gives you the headroom. Competition and sled pulling trucks typically run Stage 8 or 8.5. All stages are available with an optional ball bearing upgrade for approximately 200 RPM faster spool-up on the S300.
Turbonator® VGT Upgrade Options
Each compound kit can optionally include the Diesel Power Source® Turbonator® VGT exhaust housing on the S300 high-pressure turbo. This adds variable geometry capability for faster spool-up and exhaust braking, which the base fixed-geometry S300 does not provide.
- Base Option (Non-VGT) - Standard fixed-geometry S300 with wastegate. No exhaust brake through the turbo.
- VGT Without Exhaust Brake (+$950) - Adds Turbonator® VGT for 200-300 RPM faster spool
- VGT With Exhaust Brake (+$1,850) - Adds Turbonator® VGT with full exhaust brake capability
The Turbonator® VGT improves spool-up by 200-300 RPM and is recommended for trucks that tow regularly. It can also be combined with the ball bearing upgrade for the fastest possible low-RPM response from any compound turbo system available for the 3rd gen Cummins.
What's Included
- S300 High-Pressure Turbo (S362, S363, or S366 based on stage) with wastegate for adjustable boost
- S400 Atmospheric Turbo (S475 or S480 based on stage)
- 3-Piece High-Flow Exhaust Manifold with pre-tapped pyrometer ports
- Complete air intake with high-flow air filter
- Kevlar/Nomex lined silicone low-pressure charge pipe
- Chrome-plated aluminum high-pressure charge pipe
- Cast hot pipe with external wastegate port (not welded thin steel)
- Support bracket for atmospheric (large) turbo
- Steel braided oil supply lines for both turbos
- Stainless steel oil drain lines (two separate drains)
- Exhaust adapter to factory exhaust (bolts right to factory exhaust on 2003-2007 trucks)
- V-band clamps, T-bolt clamps, and all hose clamps
- Turbo and manifold gaskets
- All mounting bolts, oil line adapters, and installation hardware
Key Features
- Complete Kit - Both turbos, 3-piece manifold, all piping, oil lines, and hardware included
- Direct Bolt-On for 3rd Gen Cummins - No cutting or fabrication. Bolts to factory exhaust on 2003-2007 trucks.
- 250-450°F Lower EGTs - Two-stage compression runs dramatically cooler than any single turbo under load
- Near-Stock Spool-Up - S300 lights up at low RPM, S400 carries top-end airflow
- Boost Exceeds Drive Pressure - Compound efficiency approaches 1:1 boost-to-drive ratio
- Wastegated - Adjustable boost control on the high-pressure turbo
- Cast Hot Pipe - Not welded thin steel. Resists cracking under thermal cycling.
- CAD/CAM and CFD Designed - Engineered for OEM-like fit with optimized airflow
- Optional Turbonator® VGT - Add exhaust braking and 200-300 RPM faster spool
- Optional Ball Bearing - Approximately 200 RPM faster spool on the S300
- Optional Large Turbo Upgrades - S475 Billet with Race Housing (+$200) or S480 Billet with Race Housing (+$400)
Specifications
| Specification | Detail |
|---|---|
| Fitment | 2003-2007 Dodge Ram 2500/3500 with 5.9L common rail Cummins (3rd Gen) |
| Small Turbo Platform | S300 (S362, S363, or S366 depending on stage) |
| Large Turbo Platform | S400 (S475 or S480 depending on stage) |
| HP Range | 400-1,200+ RWHP (stage and supporting mods dependent) |
| EGT Reduction | 250-450°F lower under hard load vs. single turbo |
| Manifold | 3-piece high-flow exhaust manifold included |
| Emissions | No CARB exemption. Requires emissions deletion. |
| Head Stud Recommendation | At 55+ PSI sustained boost |
| Fire Ring Recommendation | At 65+ PSI sustained boost |
| Installation | Bolt-on. No cutting or fabrication required. |
Fitment
This compound kit fits 2003, 2004, 2005, 2006, and 2007 Dodge Ram 2500 and 3500 trucks with the 5.9L common rail Cummins engine (3rd generation).
These kits do not have a CARB exemption and require emissions deletion.
Have a different gen truck?
- 12V Compound Kit (1989-1998 Cummins)
- 24V Compound Kit (1998.5-2002 Cummins)
- 6.7 Cummins Compound Kit (2007.5-2018)
Need a Fummins or Chummins conversion with compound turbos? DPS builds those too.
Head Stud and Fire Ring Recommendations
- Head studs recommended at 55+ PSI sustained boost
- Fire rings recommended at 65+ PSI sustained boost
The compound system is capable of well over 55 PSI but is adjustable depending on your build. Follow proper torque specifications and break-in procedures when installing studs.
Why Diesel Power Source® for 3rd Gen Compound Turbos?
Diesel Power Source® built its reputation on compound turbo kits for Cummins diesel trucks. The 3rd gen 5.9 common rail platform was one of the first applications DPS engineered compounds for, and thousands of these kits are running on 2003-2007 trucks for towing, daily driving, sled pulling, and competition. Every kit is designed using CAD/CAM software and CFD (Computational Fluid Dynamics) testing to deliver factory-like fit with performance-level results.
- Complete Kit - Everything in one box, no hunting for parts
- 13 Stage Options - From 400 RWHP towing builds to 1,100+ HP competition setups
- CFD-Tested Airflow - Optimized piping and manifold geometry
- Bolt-On Fit - No cutting, welding, or fabrication
- Proven Platform - Thousands of kits sold for the 3rd gen Cummins
Related 5.9 Cummins Products
- S362/68 over S475 - Max 625hp- Stg 2.5
- S362/68 over S480 - Max 650hp- Stg 3
- S362/68 Ball Bearing over S475- Max 625hp - Stg 3.5
- S363/68 over S475 - Max 650hp- Stg 4
- S363/68 over S480 - Max 675hp- Stg 4B
- S363/68 Ball Bearing over S475 - Max 650hp - Stg 4.5
- S363/68 Ball Bearing over S480 - Max 675hp - Stg 4.5B
- S363/73 over S475 - Max 700hp - Stg 5
- S363/73 Ball Bearing over S475 - Max 700hp - Stg 5.5
- S363/73 over S480 - Max 750hp - Stg 6
- S363/73 Ball Bearing over S480- Max 750hp- Stg 6.5
- S366/73 over S480 - Max 1100hp - Stg 8
- S366/73 Ball Bearing over S480- Max 1100hp - Stg 8.5
Estimate your target horsepower at the rear wheels, then multiply by 1.25. For a 2003 Cummins 5.9 or 2005 Dodge Cummins turbo built for towing and daily driving, Stage 2.5 through 5 covers most builds (625–700 HP). For higher-performance 2006 Ram 2500 or 2007 5.9 Cummins turbo builds, Stage 5+ gives you more headroom. Competition and sled pulling trucks typically run Stage 8 or 8.5 (up to 1,100 HP). All stages bolt on with no cutting or fabrication.
The base compound kit uses a fixed-geometry S300, which does not provide exhaust braking. If you need exhaust brake capability, add the Turbonator® VGT with Exhaust Brake option (+$1,850) at checkout. This adds variable geometry capability to the S300 for both faster spool-up and exhaust braking. The Turbonator® VGT is recommended for trucks that tow regularly.
The ball bearing upgrade replaces the standard journal bearing in the S300 high-pressure turbo with a 360-degree ball bearing assembly. This reduces friction and allows the turbo to spool approximately 150–200 RPM faster at low RPM. It can be combined with the Turbonator® VGT upgrade for the fastest possible spool-up from any compound system available for the 3rd gen Cummins.
DPS compound kits typically reduce exhaust gas temperatures by 250–450°F compared to a single turbo at the same power level. The two-stage compression produces cooler charge air and better balanced boost-to-drive pressure ratios. Many 3rd gen owners report EGTs staying under 1,100°F even under heavy towing loads where a single turbo would push 1,400°F+.
Yes. The DPS compound kit for 2003–2007 5.9L Cummins trucks bolts directly to the factory exhaust. No cutting, welding, or fabrication is required. The kit also retains the factory battery location.
Every complete Diesel Power Source® compound kit includes both the small high-pressure turbo and the large low-pressure turbo, sized and matched to work together. Also included are the application-specific exhaust manifold, all pre-bent crossover and intercooler piping, oil feed and drain lines for both turbos with all fittings, mounting hardware, clamps, couplers, gaskets, and detailed photo installation instructions. Nothing extra needs to be sourced to complete the turbo system installation itself. Supporting components needed separately include an upgraded intercooler, 4-inch or larger turbo-back exhaust, compound-specific tuning, and fuel system upgrades depending on power target.
Owners with solid mechanical experience, a full set of hand tools, and a good working space can install a Diesel Power Source® compound kit themselves. The kits include detailed photo instructions and the team is available by phone and email for support during the installation. No welding or custom fabrication is required — every component is pre-made for the specific generation. Plan for a full weekend on a first-time DIY install, or a single day for a shop familiar with Cummins platforms. The 5.9 generations are more straightforward than the 6.7 due to the less crowded engine bay.
For 2003–2007 5.9L common rail engines, head studs are recommended at 55+ PSI sustained boost, and fire rings at 65+ PSI. The compound system is capable of well over 55 PSI but is fully adjustable. Many owners run moderate boost levels for towing without studs, but studs are strongly recommended for builds targeting 600+ HP or sustained high-boost applications.
When properly tuned and run with appropriate supporting modifications, compound turbos improve long-term reliability relative to a single turbo pushing the same power level. The primary reason is EGT reduction — cooler exhaust temperatures mean less heat stress on pistons, head gaskets, turbo bearings, and exhaust components. A truck that consistently runs 200 degrees cooler under load accumulates heat damage more slowly. The turbos themselves also benefit from working in a more efficient operating range with lower individual pressure ratios. The key qualifier is proper tuning — an improperly tuned compound setup that runs excessive fueling without matching air delivery negates these benefits.
8 Reviews
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3rd Gen Compound install and performance
I got the Stage 4 compound turbo kit. The install was a breeze. It was harder to get the old stuff off the truck. Fitment was near perfect. The stock cast down tube is a little close to the firewall, but no heat issues with the wrap DPS provided. After a heat cycle and retorque of the fasteners we put it to work my 04 2500 pulled a 6-7% grade for over 4miles at 55mph pulling 13,000lbs holding at 30lbs of boost EGTs never saw above 1100. The truck is a towing beast now. That mountain climb used to drop me to 25mph screaming on the edge of 1350 EGT. I also picked up 2 MPG on the flats. This is one bad ass kit for towing. I highly Recommend
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04 Cummins
I put one of these kits on my 04 Cummins probably 5 or 6 years ago. I have nothing but good to say about it. It has towed loads that do not belong behind a pickup, on a regular basis and has never once disappointed.....
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Compound Kit is Sweet
Not that Larry Bird. Your Add A Turbo Kit for my 2012 made a huge improvement on towing with my truck. Great power and helped with my EGT temps. Once the stock turbo goes out I plan to upgrade with the Turbonator. Thanks for making a great fitting kit
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Gday
Great choice for an aftermarket turbo, or even compounds! My DPS add on turbo kit is amazing, completely changed the truck, from EGTs, to spool and psi. Completely recommend yall!
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Hello, I
Hello,I do not normally comment on my truck part purchases, but I felt the quality of your kit was worth taking the time for. I recently purchased one of your stocker / S475 kits for my 06 ram. I have to say I am very impressed with the quality and packaging you guys do. This is my first compound turbo set up. I looked at many kits before purchasing yours. I looked at cheaper and more expensive. I had nearly talked myself into buying a cheaper kit. After receiving your kit I was immediately satisfied with spending the extra money on it. I opened the kit and was very impressed with the packaging alone. I thought to myself, if it performs half as well as it is packaged, I was going to be very happy. I had one issue after installation, but it turned out to be my fault for assuming. I assumed the tube from the output of the S475 to the input of my stock turbo was molded to the connector that uses V band clamp onto the S475. I had one extra clamp once installed and I thought it was odd, however I took the truck for a test ride and was very impressed with the faster spool up but the system got very loud and not as much boost as I had anticipated. I found out very quickly where the extra clamp went. After that mistake was remedied, the system is performing flawlessly. I am very satisfied with this kit. I look forward to putting it to the test towing in the Colorado mountains. I will be purchasing your intake for this same truck as well as probably upgrading my stock turbo to one of your new ball bearing turbos in the near future. I will not hesitate to recommend you guys to anyone who asks.
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Towing
Best thing I could have done sooner was do compounds for my 6.7Cummins! Stock fuel with some items not on the truck and it tows awesome. Steep grades and EGTs issues are a thing of the past! Great kit
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Stocker
Great compounds,makes towing a breeze with 50# of boost & egt about 300 less now
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Stocker
I bought this add a turbo kit for my 2005 Cummins and what a difference it made towing. I live in the west and travel some good mountain passes with a travel trailer. No issues with the EGTs and no down shifting. I already want to replace my stock turbo for their Turbonator turbo. Great kit! and everything came in it to install.
