HX35W Bolt-On Upgrade for Dodge Cummins 5.9

Step-By-Step Instructions

Would you like to upgrade your Dodge Cummins 5.9 Diesel turbocharger, but you're not sure how to do it? Here's How:

Please note:
This guide is based on our turbo upgrade kit for Dodge Cummins 5.9.  Not every Holset HX35W is configured the same, and as such other HX35W turbochargers may or may not fit your application. 

Follow the link if you only need to know How to install a Holset HX35W on a Dodge Cummins 5.9.

You will need:

The Turbo (buy it here)

Fasteners and Gasket (these come with the turbo kit we sell)


  • Sockets – 8mm, 10mm, 15mm. Deep 11mm
  • Ratchet and 4″ extension
  • Wrenches- 13mm, 15mm, 19mm, 21mm

Step 1: Clean the engine bay

To prevent foreign material from contaminating critical components, use water and degreaser, carwash, or equivalent means to clean the engine bay. You may want to cover your windshield to prevent oil from getting on it.

Once the engine bay is clean, and you are ready proceed to step 2

Step 2: Remove the air intake

2 a) Unclip the top of the air cleaner box then…



2 b) Use 8mm socket to loosen the hose clamp on the turbo inlet.  Remove the pipe and the top of the box together, then…


2 c) Use E12 inverted torx socket to loosen 3 plastic fasteners. then remove the lower portion of the air cleaner box.

Step 3: Unbolt exhaust flange

Remove 5 bolts and flange on the rear of the turbo.




Step 4: Disconnect oil supply line

4 a) Use 19mm wrench to hold the fitting on the turbo and use the 21mm to loosen the nut on the supply line.



4 b) Cover the end of the supply line and tuck away




4 c) Then use the 19mm to remove the fitting.


Step 5: Remove V-band Clamp 

5 a) Lubricate the threads on the v-band clamp



5 b) Use 11mm deep socket to loosen nut.


5 c) Use a flat screwdriver to pry the three sections of the clamp loose



5 d) Detach the elbow and cover.

To prevent loosing the nut you may find it helpful to thread the nut onto the shaft.



Step 6: Remove the oil drain tube

Use a ratchet and a 3-4″ extension to reach the rear 10mm bolt.

Once it is free cover the end.



Step 7: Remove Turbo from manifold



For installation instructions click here for part 2.

If you don’t find the parts you need just ask!

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If you don’t find the parts you need, just ask!