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5.9 12V Cummins 1994 – 1998

1994-1998 12V Cummins Performance Parts for 2nd Gen Dodge Trucks

S300 single turbos, compound turbo kits, and exhaust manifolds for the 1994-1998 5.9L 12V Cummins with the P7100 injection pump.

The 1994-1998 5.9L 12V Cummins pairs a strong mechanical engine with the Bosch P7100 inline injection pump, one of the most upgradeable mechanical fuel systems made. The pump responds directly to more air with no electronic interference, no derating, and no tuner. The factory HX35 runs out of airflow quickly once the fuel is turned up, so Diesel Power Source® sizes each turbo to the pump work the truck has.

Built for the P7100

Turbos sized to the pump work, from stock to a full build

No Tuner Required

Mechanical injection responds directly to more air

2nd Gen Fitment

Built for the 1994-1998 Dodge Ram 2500 and 3500

Lower EGTs

Single turbos and compound kits both cut exhaust heat under load

What Fits a 1994-1998 12V Cummins

  • S300 single turbo: Replaces the factory HX35 at the T3 flange. Five configurations from the S362 to the S369, with journal or ball bearing.
  • Add-A-Turbo kit: Keeps the factory turbo and adds an S475 in front of it.
  • Compound turbo kit: An S300 small turbo with an S475 or S480, plus the manifold, piping, oil lines, and hardware.
  • T3 exhaust manifold: A 3-piece center-mount manifold cast from HSMD that flows approximately 23% more than the factory manifold, with a matching hardware and gasket kit.
  • Turbonator® VGT: Variable geometry for the S300, with exhaust brake capability on the electronic version.
  • Ball bearing turbo: Spools approximately 200 RPM sooner at the same horsepower.

1994-1998 12V Cummins Specifications

  • Engine: 6BT 5.9L, 359 cubic inches
  • Fuel system: Bosch P7100 inline mechanical injection pump
  • Factory power: approximately 180 HP at 2,500 RPM and 420 lb-ft at 1,600 RPM
  • Factory turbo: HX35
  • Turbo flange: T3
  • Chassis: 2nd Gen Dodge Ram 2500 and 3500

Turbo Sizing by P7100 Pump Work

Pump Work What Has Been Done Fuel Capability (approx.) Turbo Direction
Stock No modifications About 180 HP S362 single
Light Fuel screw, AFC adjustment, mild injectors 250-400 HP S362 single or an Add-A-Turbo kit
Moderate Governor springs, delivery valve work, partial fuel cuts 400-550 HP S362 or S363 single, or an S362 over S475 compound kit
Heavy Full fuel cuts, high-flow delivery valves, custom cam plate, oversize injectors 550-900 HP S366 single below 650 HP, or a compound kit sized to the goal
Full build Large plungers and barrels, custom cam, full delivery valve upgrade 900 HP and up The largest compound configuration. Call DPS to size it.

Size the turbo to the pump, not to the model year. A stock P7100 and a fully built P7100 need very different turbos. Figures are approximate and vary with injectors, air supply, and supporting modifications.

Upgrade Paths for the 1994-1998 12V Cummins

Daily Driver and Moderate Towing (350-450 HP)

An S362 or S366 single turbo with a fuel screw adjustment and a 3-inch exhaust.

Heavy Towing and Street Performance (450-550 HP)

A larger single turbo with governor springs and fuel cuts and a 4-inch exhaust, or a compound kit for towing.

Competition and High Power (550-800+ HP)

Compound turbos with a full P-pump build, a built transmission, and supporting modifications.

HP figures are approximate rear wheel horsepower. Not sure where your pump falls? Call 801-930-8404 with the work that has been done.

Before You Order

  • Fits 1994-1998 Dodge Ram 2500 and 3500 with the 5.9L 12V Cummins.
  • Tell DPS what pump work the truck has: fuel screw, governor springs, fuel cuts, delivery valves, or a custom cam.
  • S300 single turbos need a 4-inch downpipe on 12V trucks. It is sold separately.
  • Some trucks with the 47RH or 47RE automatic need the transmission oil cooler on the side of the block relocated.
  • 12V heads have rectangular exhaust ports. Use a 12V manifold, not a 24V manifold.

Good to Know

  • Expect roughly 10 HP per PSI of boost on a 5.9L Cummins.
  • Head studs are recommended above 45 PSI of boost on 12V engines.
  • The factory transmission typically needs attention around 400 RWHP.
  • The 12V has the strongest stock rods. They are reliable to about 800 RWHP on stock bolts.
  • DPS S300 and S400 turbos are oil cooled. No coolant lines are required.
  • Warranty coverage varies by product under the Diesel Power Source® PMA. Registration within 14 days of purchase is required.

Helpful 12V Cummins Guides

Shop by category: 5.9 Cummins Turbos | 5.9 Cummins Manifolds | Compound Turbo Kits | All 5.9 Cummins Parts. Other years: 1989-1993 12V and 1998.5-2002 24V. Free shipping on orders over $350.

Cummins is a registered trademark of Cummins Inc. Diesel Power Source® is not affiliated with Cummins Inc.

1994–1998 Dodge Cummins 12V – Frequently Asked Questions

It has the Bosch P7100 inline injection pump, which arrived in 1994. The P7100 is mechanical, highly tunable, and can be built across a wide range, from a fuel screw adjustment to a full high-output pump. With no ECM, the engine responds directly to more fuel and more air, and no tuner is required.

Size the turbo to the pump work, not the model year. A stock or lightly adjusted pump is well matched to an S362 single. Governor springs and partial fuel cuts move the truck to an S362 or S363 single or a small compound kit. Full cuts and delivery valves call for an S366 single below 650 HP or a compound kit. Tell DPS what has been done to the pump.

Yes. A mechanical engine cannot limit itself, so adding fuel without adding air raises EGTs. A turbo upgrade lowers EGTs at the current fuel level and gives you room to add fuel safely afterward.

For moderate towing, an S362 or S366 single. For heavy towing or higher power, a compound kit: the small turbo spools early under load and the large turbo supplies air on long grades. Compound kits give the largest EGT reduction in the DPS lineup.

It replaces the fixed turbine housing on an S300 with a variable geometry housing that spools 200-300 RPM sooner. The electronic version also adds exhaust brake capability.

An S300 single needs a 4-inch downpipe, sold separately. Head studs are recommended above 45 PSI of boost. The factory transmission typically needs attention around 400 RWHP. The stock rods are reliable to about 800 RWHP on stock bolts.

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