Variable Geometry Turbocharging for Ford 6.0L Diesel (2003–2007)
The Turbonator® VGT is a Variable Geometry Turbocharger engineered from scratch for the Ford 6.0 Powerstroke diesel engine. Unlike OEM turbos or rebuild-only options, the Turbonator® combines aerospace-grade stator technology with the S300 turbo platform to deliver fast spool-up, lower EGTs, and 12–20% power gains on 2003–2007 Ford Super Duty trucks. Whether you’re towing heavy loads, reducing exhaust temperatures, or adding clean power for daily driving, the Turbonator® VGT is the most advanced Ford 6.0 turbo replacement available.
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The Diesel Power Source® Turbonator® VGT is a complete S300-based Variable Geometry Turbocharger for 2003–2007 Ford Super Duty trucks with the 6.0L Powerstroke diesel engine. This is the only S300 VGT on earth built specifically for the Ford 6.0 turbo replacement market. Built on the proven BorgWarner S300 turbo platform, the Turbonator® spools lightning fast, handles as much as 800 HP, cools EGTs significantly, and improves fuel mileage.
Available in five turbo size configurations from 450 HP to 530 HP, with optional ball bearing upgrade for 150–200 RPM quicker spool-up. Whether you’re building a 2003 Ford 6.0 for towing, a 2005 Super Duty turbo upgrade for daily driving, a 2006 F-350 turbo replacement for reliability, or a 2007 6.0 Powerstroke turbo platform for performance, DPS has a Turbonator® sized for your goals.
The 2003–2007 6.0L Powerstroke is one of the most common diesel platforms for turbo replacement. Factory turbos on these engines have a limited service life, and turbo failure is one of the most frequent wear items on the 6.0 diesel. OEM replacement turbos are expensive, and rebuild kits simply return you to stock performance with the same fixed-stator limitations.
The Turbonator® VGT solves this problem with variable geometry stator vanes that automatically adjust throughout the RPM range. On the low end, the closed stators spool the turbo quickly like a small turbo, delivering instant throttle response. On the top end, the open stators allow maximum airflow and the turbo performs like a much larger unit. This is why Turbonator®-equipped Ford 6.0 trucks consistently produce 12–20% more horsepower with dramatically lower EGTs than the same truck on a factory turbo.
CFD Tested: When the Turbonator® VGT stators were CFD tested against the Ford 6.0 Powerstroke factory turbo and Garrett turbos, testing showed the DPS turbine housing is significantly more efficient at putting exhaust energy into the turbine wheel, flows better overall, and makes more power.
| Stage | Configuration | Max HP | Best For |
|---|---|---|---|
| Stg 1.5 | S362/68/.70 | 450 HP | Budget builds, mild towing, daily driving |
| Stg 3 | S363/68/.70 | 500 HP | Daily driving + occasional towing |
| Stg 3.5 | S363/68/.70 Ball Bearing | 500 HP | Same as Stg 3 with 150–200 RPM faster spool |
| Stg 4 | S363/73/.80 | 530 HP | Performance builds, heavy towing, EGT priority |
| Stg 4.5 | S363/73/.80 Ball Bearing | 530 HP | Same as Stg 4 with ball bearing spool |
How to choose: For a Ford 6.0 turbo upgrade focused on towing and daily driving, Stage 1.5 through 3.5 covers most builds. For heavier towing or performance-oriented applications, Stage 4 or 4.5 gives you more airflow headroom with the larger 73mm turbine wheel. Ball bearing upgrades add 150–200 RPM faster spool for drivers who prioritize responsiveness.
Exhaust Brake Note: The exhaust braking function with the Turbonator® VGT will always increase exhaust pressure while braking, however, Diesel Power Source® does NOT guarantee a specific exhaust braking force as every truck and application will be different.
The DPS Turbonator® VGT / VNT are performance S300 & S400 based Variable Geometry Turbochargers, designed with aerospace-grade stator technology making them extremely robust and durable. The patented and patent-pending stator housing can be clocked independently to fit multiple applications. The ultra-efficient stators improve spool-up time by up to 400 RPMs, lower EGTs, and improve fuel mileage.
The Turbonator® comes in pneumatic or electronic options. Unlike modified stock Ford 6.0 turbos with small stock housings and stock parts, the Turbonator® is a completely new, from-scratch, innovative VGT / VNT made for performance applications. It is unique enough to receive more than one patent. Because the Turbonator® is based on the S300 and S400 turbo platforms, they flow much more air and exhaust, keeping down drive pressures, and allowing a greater than 1:1 exhaust drive to boost pressure ratio, which is virtually impossible with other turbos.
The OEM Ford 6.0 diesel turbo replacement costs are outrageous, and Ford 6.0 turbo rebuild kits can be sketchy business especially if you don’t have your own balancing machines — and you simply get a stock turbo when you’re done. The Turbonator® VGT for Ford 6.0 turbo kit will give your truck much cooler EGTs, lower the drive pressure below boost pressure, and improve your power by approximately 12–20%. No other single turbo can do that.
Because of the ability to have higher boost over drive pressure you get unmatched performance, especially on tuned Ford 6.0 Powerstroke trucks. If you’re looking for a 6.0 non-VGT turbo or 6.0 Powerstroke non-VGT turbo, try the Turbonator® VGT first — this is much different in size, performance, and technology from the factory 6.0 Powerstroke VGT turbo.
Need help sizing? We’re happy to talk to you and answer any questions. Let us help you size a proper turbo to your application. Many times we can prevent you from purchasing the wrong turbo with just a simple phone call. Call 801-930-8404.
This turbo kit fits 2003, 2004, 2005, 2006, and 2007 Ford Super Duty trucks with the 6.0L Powerstroke diesel engine (F-250, F-350, F-450, F-550, Excursion).
Installation: Direct bolt-in to factory turbo location. Requires removal of factory turbo and installation of new actuator. No piping modifications needed — uses factory oil lines and intercooler piping.
Tuning: Works with factory ECU or aftermarket calibrations. The 3-stage mechanical actuator adjusts stator position based on boost pressure and engine load, not electronic commands. Consult your tuner before installation if already modified.
Emissions: Does not affect DPF, EGR, or emissions equipment. All factory systems remain compatible.
How does the Turbonator® VGT differ from factory Ford 6.0 turbos?
The factory Ford 6.0 turbo uses fixed stator vanes and smaller wheel sizes optimized for OEM power levels. The Turbonator® VGT features movable stator vanes (Variable Geometry) that automatically adjust throughout the RPM range, combined with larger, more efficient wheel sizes. This allows the Turbonator® to spool faster, flow more air, and produce measurably more power while keeping EGTs cooler.
What’s included in the kit?
The Turbonator® VGT includes the turbocharger, 3-stage mechanical actuator, oil supply and drain lines, mounting hardware, and gaskets. No piping modifications are needed — the Turbonator® uses factory oil lines and factory intercooler piping. Many Ford 6.0 owners complete the swap in 4–6 hours.
Will it work with my factory ECU or aftermarket tuning?
Yes. The mechanical actuator adjusts stator position based on boost pressure and engine load, not electronic commands — it operates passively without ECU reprogramming. If your truck is already tuned, the Turbonator® will respond to your existing tune. Consult your tuner before installation if already modified.
How much power will I gain?
Expect 12–20% RWHP increases depending on turbo size and tuning level. Example: A stock 6.0 Powerstroke at 300 RWHP might see 360–420 RWHP with the S363/73/.80 installed. Ball bearing upgrades add responsiveness but not additional HP.
Will the Turbonator® reduce my EGTs?
Yes. Turbonator® VGT units typically lower EGTs by 10–20% under the same load conditions compared to factory turbos. If your stock turbo runs 1,200°F while towing, the Turbonator® might run 1,000–1,080°F under identical conditions. Lower EGTs mean safer towing and extended engine life.
Is the Turbonator® a direct replacement for my factory turbo?
Yes. The Turbonator® VGT bolts directly into the factory turbo location on 2003–2007 Ford 6.0 Powerstroke engines. No modifications to engine bay brackets, piping, or oil lines are required. Factory intercooler, intake, and exhaust components remain unchanged.
Can I use the Turbonator® in a compound (twin-turbo) setup?
Yes. The Turbonator® VGT can be used as the primary (high-pressure) turbo in a compound turbo system. It pairs well with a larger atmospheric turbo (S400 platform). Consult DPS sales for compound kit recommendations.
Is tuning required?
No. The Turbonator® VGT works out-of-the-box with factory tuning. Many customers pair it with an aftermarket ECU tune to optimize fuel load and boost pressure for maximum power. Tuning is optional but recommended for performance builds.
What is the difference between ball bearing and journal bearing?
The standard Turbonator® uses journal bearings (oil-lubricated). The optional ball bearing upgrade uses ball bearings with less rotational resistance, reducing turbo lag by 150–200 RPM. Ball bearing upgrades cost approximately $550 more and are recommended for drivers who prioritize responsiveness.
Does the Turbonator® have a warranty?
Yes. The Turbonator® VGT is covered by a standard manufacturer’s warranty. Details are available on the product page or by contacting Diesel Power Source® sales at 801-930-8404.
