17 March 2017 1045780-94 Dodge Cobra Kit (I-00377) 1 BD Twin Turbo Cobra Kit 2003-2012 Dodge HPCR Machined BD turbochargers only BUILDERS KIT Installation reccomendations to aid asssembly Does not include detailed instructions This is an installation guidline. Do not attempt without installation expereience. Read installation notes prior to install. This kit will require a race tuner and deletion of the EGR cooler. UNLESS AN EO# IS LISTED, THIS PRODUCT IS LEGAL IN CALIFORNIA. FOR RACING VEHICLES ONLY, WHICH MAY NEVER BE USED UPON A HIGHWAY.
17 March 2017 1045780-94 Dodge Cobra Kit (I-00377) 2 Order Guide Kit PN Years BD Cobra Kit Secondary Turbo Turbo Turbine Primary Turbo 1045780 03-07 361 SXE 76mm - 1.0AR 476 SXE 1045781 08-09 361 SXE 80mm - 0.9AR 476 SXE 1045782 10-12 361 SXE 80mm - 0.9AR 476 SXE 1045783 03-07 364.5 SXE 80mm - 0.9AR 480 SXE 1045784 08-09 364.5 SXE 80mm - 1.0AR 480 SXE 1045785 10-12 364.5 SXE 80mm - 1.0AR 480 SXE 1045794 03-07 366 SXE 80mm - 1.0AR BD 486 1045786 08-09 366 SXE 80mm - 1.0AR BD 486 l1045787 10-12 366 SXE 80mm - 1.0AR BD 486 1045793 03-07 S467 83mm - 1.0AR 488 SXE 1045791 08-09 S467 83mm - 1.1AR 488 SXE 1045792 10-12 S467 83mm - 1.1AR 488 SXE Name Inducer Size Potential Crank Horsepower Min Rated Peak Max Flow (Lb/min) *RPM to Spool **Transient Response BD Single Turbo Kit Guide Super B Single 58mm 200 400 450 57 1250 0 Super B Killer 63mm 250 500 525 76 1800 30 Super B Killer SXE 61mm 250 500 525 77 1800 15 Super B Special 64.5mm 300 550 600 77 1800 36 Super B Special SXE 63mm 300 550 600 79 1750 32 Super B 600 66mm 375 600 650 78 1800 37 Super B 600 SXE 64.5mm 375 600 650 82 1750 35 Super B 650 67mm 450 650 675 80 1750 47 Super B 650 SXE 66mm 450 650 675 87 1925 39 Super B 700 SXE 69mm 575 675 700 98 2125 44 Rumble B (369 SXE) 69mm 575 675 725 98 2125 44 Rumble B (467) 67mm 575 675 700 92 2225 43 Rumble B (472) 72mm 600 775 800 110 2375 57 S476 SXE 76mm 700 825 850 121 2550 63 S480 SXE 80mm 800 925 950 134 3050 75 BD 486 86mm 900 1000 1050 144 3050 80 S488 SXE 88mm 900 1075 1125 160 3325 79 S588 SXE 88mm 900 1100 1150 162 3450 85 S594 SXE 94mm 1100 1275 1325 187 3850 87 K44 107mm 1300 1400 1500 197 4950 95 BD Compound Turbo Kit Guide Tow Twin 58mm/66mm 250 600 625 78 1150 5 RT700 58mm/71mm 300 675 700 98 1250 10 RT850 64.5mm/74mm 400 800 850 103 1675 39 Cobra 76 61mm/76mm 400 800 900 124 1650 27 Cobra 80 64.5mm/80mm 450 1000 1050 134 1700 36 Cobra 86 66mm/86mm 550 1100 1200 144 1800 46 Cobra 88 67mm/88mm 675 1225 1400 160 2100 49 BD Triple 74mm/2x74mm 800 1525 1600 204 2200 64 *Suggested RPM based on 5.9L 24V. Value will vary depending on engine application, displacement, turbine selection and supporting modifications **Estimated turbocharger response comparison
17 March 2017 1045780-94 Dodge Cobra Kit (I-00377) 3 Kit Contents 1045996-T4 1045986-T4 1405445 Manifold; with Wastegate Port Exhaust Manifold Gasket Set LP Turbo Bracket Qty: 1 Qty: 1 Qty: 1 1405438 1405442-1 1405442-2 1453522 Battery Box Air Box Air Box Support Blanket: T4 Turbine Qty: 1 Qty: 1 Qty: 1 Qty: 1 2925 CU-3970875 CU-3934084-1 1405434 Oil Drain- Coolant Tube 5 Air Filter Oil Drain-Primary Secondary 5/8 Qty: 1 Qty: 1 Qty: 1 Qty: 1 1453130-B 1453820 1405453 1453723-3 Turbo Oil Feed (-6JIC 90 x - Bracket; Front 1-1/8 Barb x Air Intake Seal 6JIC) Mount ¾ NPT Qty: 2 Qty: 20 & 27 Qty: 1 Qty: 1
17 March 2017 1045780-94 Dodge Cobra Kit (I-00377) 4 Mounting Hardware 1900037 1505016 11864 1100111 M6-1.0x12mm Flange Nut; Jam M6x1 M6-1.0 U-Nut ¼ Washer Qty: 8 Qty: 2 Qty: 5 Qty: 3 1401553 1120125 1120124 FT-0413922 M8 Flange Nut Insulated Clamp 1 M8-1.25mm Bolt #152 Viton O-Ring Qty: 1 Qty: 2 Qty: 3 Qty: 1 FT-0424690 1453726-1 1453726-2 1453137 #244 Viton O-Ring Gasket; Dodge MAF Gasket; Dodge IAT 5.9L O-Ring; 10mm x 2.5 Qty: 1 Qty: 1 Qty: 1 Qty: 1 1453126 1453127 FT-11116245 1462441 Support Bracket Bolt Support Bracket Bolt; Flange Nut M10-1.5mm (M10x1.5x20) Washer (M10) M8x1.25 Qty: 2 Qty: 2 Qty: 2 Qty: 2
17 March 2017 1045780-94 Dodge Cobra Kit (I-00377) 5 1453117 1453162 FT-0173590 1453135 Turbo Oil Inlet Adapter ORB-6JIC 1/8 NPT x -6JICM #8-32 SS Screw (1/4MPTx-6JIC) Fitting Qty: 1 Qty: 2 Qty: 4 Qty: 1 121-D 1456735 FT-90700 Hex Plug; ½ 5/8 barb x1/2 NPT Nut; M6x1 Flange Qty: 1 Qty: 1 Qty: 1 Boots & Clamps 1302198 1453113 1604056 1405441 Clamp; Spring Clamp; 1-1/4 Coolant Line 1- Hose; Heater 5/8 26mm Gear 1/8 x5/8 Qty: 6 Qty: 1 Qty: 8 Qty: 1 1405446 99800-0450 1405625 1401563 TCC Coolant Line Clamp; V-Band Clamp; V-Band Boot; Silicone 5/8 4.5 4.72 3.5 x3.5 Qty: 1 Qty: 1 Qty: 1 Qty: 1
17 March 2017 1045780-94 Dodge Cobra Kit (I-00377) 6 1405212 1405211 1453221-1 HS-96 Clamp; 3.56 - Clamp; 3.0 - Boot; Silicone Clamp; 5"-7" 3.91 3.38 3 x3.5 Qty: 5 Qty: 1 Qty: 1 Qty: 3 99502-0588 90368B P103516-1 5 Stainless Steel Down Reducer; 5 x5.5 Clamp; V-Band 5.88 Pipe Clamp Qty: 1 Qty: 1 Qty: 1 Piping 1405431 1405432 1405435 5 Primary Inlet 3.5 Primary Outlet 3.5 Secondary Inlet Qty: 1 Qty: 1 Qty: 1
17 March 2017 1045780-94 Dodge Cobra Kit (I-00377) 7 1405440 1405447 Cobra Casting Downpipe 5 Exhaust Downpipe Qty: 1 Qty: 1 Cobra S400 Mounting Hardware 1405439 1462431 1462429 1462441 RG-VT10481 Stud M10- Stud M10- Nut M10- S400-T6 Hot Pipe 4.81 V-Band Clamp 1.5 x 25 1.5 x 35 1.5mm Qty: 1 Qty: 2 Qty: 4 Qty: 6 Qty: 1 Cobra S300 SX-E Mounting Hardware 1405454 FT-32826 1452429 1120033 1462441 RG-10216-1 SXE-T6 Hot Stud 3/8 - Stud M10- Nut 3/8 Nut M10-4.2 V-Band Pipe 16 1.5 x 35 NC 1.5mm Clamp Qty: 1 Qty: 2 Qty: 4 Qty: 2 Qty: 4 Qty: 1
17 March 2017 1045780-94 Dodge Cobra Kit (I-00377) 8 Year Dependent Parts 2003-2009 FT-69884 1456740 1405437 1401563 Fitting; ¾ NPTx ¾ NPT 90 Plate; MAF Block Off 3.5 CAC Inlet Tube 03-09 Boot; Silicone 3.5 x3.5 Qty: 1 Qty: 1 Qty: 1 Qty: 1 Years 2010-2012 1453723-1 1453723-2 1405433 1302425 Fitting; ¾ NPTx ¾ NPT 90 Deg Fitting; Barb 1-1/8 x ¾ NPT 3.5 CAC Inlet Tube 10-12 Qty: 1 Qty: 1 Qty: 1 Qty: 1 1405426 1405428 1405427 Boot; Silicone 3.25 x3.5 Coolant Tank Plug; 1 Barb Heater Hose; 4 Qty: 1 Qty: 1 Qty: 4 1453724 1120126 Tube; Crank Breather 6.7L Clamp; 11/16-1.5 Qty: 1 Qty: 2
17 March 2017 1045780-94 Dodge Cobra Kit (I-00377) 9 Turbocharger Oil Feed/ Drain Layout (Primary/ Secondary) Item No. Part No. Description Qty 1 1462431 1 STUD; M10 x 1.5 x 025 2 FT-32826 2 STUD;3/8-16x2" 2 2 CU-3970875 Oil Drain; Cummins Primary 1 CU-3934084-1 Oil Drain; Cummins Secondary 1 3 1462441 1 NUT; M10x1.5 Small Flange 2 1120033 2 NUT, 3/8 NC 2 4 1453162 Turbo Oil Inlet 1/4MPT X -6JIC 2 5 1453130-B -6JIC 90 X -6JIC HOSE 2 6 1453135 Fitting; ORB x -6 JIC 1 1453117 Adapter; Oil Feed 1/8NPT x -6MJIC 1 7 1453137 10mm O-ring 1 8 1453123 Drain; Block Adapter 1
17 March 2017 1045780-94 Dodge Cobra Kit (I-00377) 10 Coolant Lines Layout Item No. Part Number Description Qty. 1 1405434 Coolant Tube; Dodge 5/8" Line 1 2 FT-69884 3 Fitting;3/4NPT x 3/4 NPT 90d 1 3 1453723-2 4 Fitting; Coolant Hose Clamp 1 4 1453723-1 4 Fitting; Coolant Hose Block 1 5 1453723-3 Fitting; Barb 1.125"-3/4" 1 6 1405441 Coolant Line;1-1/8x 5/8x 6.25L 1 7 1302198 Clamp; Spring CTB-26mm 4 8 1453113 Clamps;1-1/4 Gear (HS12) 1 9 1604056 Hose; Heater 5/8" ID (in) 8" 10 1405446 Coolant Line; Dodge 5/8" TCC S 1 11 1120125 Clamp; Insulated 1"(900729-23) 2 12 1401553 Nut, M8 Flange 1 13 1120124 Bolt, M8-1.25 Flange 3 14 1405453 Bracket; Engine Hoist Mount 1
17 March 2017 1045780-94 Dodge Cobra Kit (I-00377) 11 Turbocharger and Piping Layout
17 March 2017 1045780-94 Dodge Cobra Kit (I-00377) 12 Item No. Part No. Description 1 1045996-T4 Manifold; T4 Waste gate 1 2 1405445 Bracket; T6 Primary Support 1 3 1453126 M10 x 1.5 - Mounting Bracket Bolts 2 4 1453127 M10 x 1.5 - Mounting Bracket Washer 2 5 Primary Turbo 6 1405439 1 Adapter;T6 S400 HM Hot Pipe 1 1405454 2 Adapter;T6 S300 SX-E HM Hot Pipe 1 7 1462429 STUD; M10 x 1.5 x 035 4 8 2405021 T6 Dual Volute Gasket 1 9 1462441 NUT; M10x1.5 Small Flange 8 10 1462431 STUD; M10 x 1.5 x 025 4 11 2475052 T4 Dual Volute Gasket 1 12 Secondary Turbo 13 1405430 1/5 Adapter; FM V-Band S400 4" 1 14 1405236 2/5 Adapter; HM V-Band S300 3.75 1 15 RG-VT10481 1 Clamp; V-Band 4.81" (.207") 1 RG-010650 2 Clamp; V-Band 4.21" (.14") 1 16 1405432 Pipe; Primary Outlet Tube 1 17 FT-0413922 O-ring; #152 (.139) 3.25" Viton 1 18 1401563 Boot; Silicone 3.5"x 3.5" 4ply 1 1401563 3 Boot; Silicone 3.5"x 3.5" 4ply 1 19 1302425 4 Boot; Silicone 3.25 x3.5 4ply 1 20 1405212 Clamp; 3.56-3.91 5 21 99800-0450 Clamp; V-Band 4.50" 1 22 1405435 Pipe; Secondary Inlet 1 23 FT-0424690 O-ring; #244 Viton(.139) 4.25id 1 24 1405625 Clamp; V-Band 4.72 1 25 P103516 Reducer Sleeve; 5 1/2" x 5" 1 26 HS-96 Clamp; 5" - 7" Worm Gear 2 27 1405431 Pipe; Primary Intake 1 28 1453726-1 Gasket; Dodge MAF 1 29 1453726-2 Gasket; Dodge IAT 1 30 1456740 3 Plate; MAF Block Off BD Intake 1 31 FT-0173590 Screw;#8-32 x 9/16 Pan Head SS 4 121-D 3 Hex Plug; ½ 1 1456735 4 5/8 x 1/2 Npt 1 32 1405437 3 Pipe; CAC 3.5" 03-09 1 1405433 4 Pipe; CAC 3.5" 10-12 1 33 1405211 Clamp; 3.00-3.38 1 34 1453221-1 1 Intercooler Boot 3"-3.5" x 4" 1 1401532 2 Intercooler Boot 2.75"-3.5" x 5" 1 35 1405440 Cobra Casting; 5 Downpipe 1 36 99502-0588 Clamp; V-Band 5.88" 1 37 90368B Clamp; SS Exhaust Lap 5" 1 38 1405447 Exhaust; Dodge S400 Twin Downpipe 1 39 121-D 3 Plug; Hex Head ½ NPT 1 40 1453735 4 Fitting, 5/8 Barb x ½ NPT 1 41 1453724 4 Tube; Crank Breather 1 1 Included with S400 Cobra kit 2 Included with S300 SX-E Cobra kit 3 Included in 2003 2009 vehicles 4 Included in 2010 2012 vehicles 5 Installed on compressor cover Qty
17 March 2017 1045780-94 Dodge Cobra Kit (I-00377) 13 Air Box & Battery Tray Layout Item No. Part Number Description Qty. 1 1405442-1 Air Box 1 2 1405442-2 Air Box Bracket 1 3 1505016 Nut; Jam M6x1.0 2 4 1900037 Bolt; M6-1.0x12 6 5 1405438 Battery Box 1 6 11864 U Nut; M6-1.00 Extruded 5 7 1100111 Washer, Flat - 1/4" 3 8 2925 Air Filter 1 9 HS-96 Gear clamp 1 10 1453820 Air Intake Seal 20 11 1453820 Air Intake Seal 27"
17 March 2017 1045780-94 Dodge Cobra Kit (I-00377) 14 Installation Notes & Recommendations BUILDERS KIT DOES NOT INCLUDE STEP-BY-STEP INSTRUCTIONS THIS IS AN INSTALLATION GUIDELINE. DO NOT INSTALL WITHOUT PREVIOUS TURBO INSTALLATION EXPERIENCE. Recommendations: - Remove passenger battery, battery box, fender liner, 2 nd oil drain frost plug, and coolant lines near turbo. Drain the coolant and A/C system prior to install. - 2010-2012 trucks will require the coolant bottle to be removed. - Remove the passenger side shock tower and shock. - The AC lines and transmission dip-stick tube will need to be re-shaped to fit. - If you have a steel receiver/dryer, we recommend replacing it with an aluminum one to help persuade lines into place. - Install the ¼ NPT x JIC oil feed lines and oil drain studs prior to turbo install. - Install the exhaust manifold and gaskets (1045996-T4 & 1045986-T4), but do not install studs on the T4 outlet. Ensure the waste gate port is facing downward. - Install coolant lines 1405446, 1405434, and 1405441. 2003-2007 trucks will require the use of the included 90 degree NPT fitting and 1453723-3. 2010-2012 will require installation of the NPT adapter block 1453723-1, 1453723-2, and 1453723-3. - Mount 1405446 using 2x insulated clamps (1120125). Use supplied stud on the primary turbo mounting bracket and M8 threaded hole on cylinder 6 fuel line protector. - 2008 and onward trucks will require the engine hoist mount to be replaced (1405453). Remove alternator and replace bracket. - Install primary turbo bracket (1405445) with the bolts ½ turn away from tight (the bracket should be able to move slightly). Tighten these bolts after the hot pipe has been attached to the secondary turbo. - Install the 4x (1462429) 35mm long studs into the hot-pipe. Mount the hot pipe (1405439/1405454) to the 96mm turbine housing using a T6 dual volute gasket and 2x M10 nuts (1462441). The remaining 2x M10 nuts will be installed after the turbo is mounted.
17 March 2017 1045780-94 Dodge Cobra Kit (I-00377) 15 - Mount the battery box and battery. Insert U-nuts to battery box for grid heater relay, air box support, and OEM battery tie down mount prior to installing the battery box. - Push on the supplied 5 M6x1 U- nuts onto the battery box 1405438. - Re-use the OEM battery tie down bracket by bolting it into the supplied M6 U-nut. - Loosen the turbo cartridge clamps (do not remove clamps) and orient the turbine housing and compressor cover in the configuration shown (orient for installation only). Re-tighten the clamps before moving the turbo. - Install the primary turbo onto the primary turbo bracket (1405445) and install the remaining M10 nuts to hand tight. - Install the remaining 4x M10 studs, T4 gasket, and waste gate or waste gate cap onto the T4 exhaust manifold. - Mount the secondary turbine housing onto the manifold. Align the hot-pipe up with the secondary turbine housing and attach using the supplied V-band clamp. Tighten the primary bracket (1405445) bolts and M10 nuts after the turbine outlet clamp is tight. - Install the primary and secondary turbo oil drain and feed lines. - 2010-2012 trucks will require the coolant overflow tank 1405426 to be installed. Use the supplied 1 plug 1405428 and 1 hose to plug the bottom drain. Clip the coolant tank onto the battery box and fasten in place with supplied M6 bolt and nut. Connect the radiator overflow hose onto the vertical barb. - Install the primary outlet tube (1405432) with supplied O-ring prior to installing the secondary inlet tube (1405435). Ensure the O-ring is not pinched or torn during install. - Install air box bracket 1405442-2 with 2x M6 bolts, nuts, and washers to 1405442-1 - Clock the secondary compressor cover to ensure the CAC tube does not interfere with the hood or plastic cowling. Centre the boots and ensure all clamps installed behind any tube beat to keep boots from slipping. - Mount 20 of 1453820 to 5 inlet diameter of air box. Mount 27 of 1453820 to upper edge of air box. - Boot locks are recommended to be installed on both sides of the 3.5 CAC tube. Due to hood clearance, it is recommended to install boot-lock mounts on the underside of the compressor cover outlet/ CAC tube.