6.0 Powerstroke S400 Turbo Kit - Unlock Your Truck's True Potential

Introduction to the 6.0 Powerstroke S400 Turbo Kit

If you're a diesel truck enthusiast, there's a good chance you've heard about the legendary 6.0 Powerstroke engine produced by Ford between 2003 and 2007. While powerful, the 6.0L was plagued with issues from the factory, leaving many owners frustrated. Fortunately, there are solutions to unlock the true potential of these trucks, with one of the most popular being swapping to a larger S400 turbocharger.

S400 turbos, produced by companies like BorgWarner, feature a 62mm inducer and can flow around 80-100lbs of boost pressure. That's a significant upgrade over the stock 64mm turbo on the 6.0L Powerstroke. With an S400 installed, these trucks can safely produce 600-800 horsepower to the wheels, transforming them into tire-shredding monsters.

Benefits of the S400 Turbo Swap

Let's look at some of the main benefits of swapping to an S400 turbo on your 6.0L Ford:

• Huge power gains - Expect 160+ extra horsepower to the wheels with supporting mods.
• Improved engine longevity - The S400 flows better and reduces EGTs.
• Greater tuning potential - Supporting mods like head studs allow massive power.
• Sound - The whistle from an S400 turbo is simply intoxicating!
• Durable design - S400s are built to withstand big power levels.

As you can see, an S400 swap addresses some of the main shortcomings of the 6.0L Powerstroke while transforming it into an absolute beast. Many diesel fans argue the S400 is the single best modification you can make to these trucks.

What's Included in an S400 Turbo Kit

Many companies offer complete S400 turbo kits to make the process of upgrading your turbocharger simple and straightforward. Here are some of the main components included:

• S400 turbocharger - The star of the kit, capable of flowing 65-85 pounds of boost.
• Discharge pipe - Connects the S400 turbo to the intake.
• Oil drain kit - Drains oil from the S400 turbo back to oil pan.
• Gaskets - For a leak-free install.
• Hardware - Necessary nuts, bolts, clamps etc.
• Tuner - A critical supporting mod that adjusts tuning.

Reputable diesel shops like Blessed Performance offer complete S400 turbo kits that come with everything you need for a smooth install. Expect to pay around $4,000-$5,000 for a quality kit and supporting mods.

Installing an S400 Turbo on a 6.0 Powerstroke

Difficulty Level

While swapping in an S400 turbo certainly isn't for the faint of heart, it's also not an overly complex job if you have mechanical skills and ability. The entire install can typically be completed in a full weekend by a home mechanic. There are also many excellent video tutorials online. However, you may want an experienced diesel shop to tackle it if you're not up for a project.

Steps for Installation

Here is an overview of the S400 turbo install process on a 6.0L Ford Powerstroke:

1. Remove stock turbo, oil and coolant lines, intake tube, etc.
2. Install oil feed and drain fittings on S400 turbo.
3. Mount S400 turbo using supplied hardware and gaskets.
4. Connect oil and coolant lines to S400 turbo.
5. Install discharge pipe from S400 compressor to intake.
6. Plug in electronic S400 wastegate actuator.
7. Finish by upgrading fueling, install tuner, and custom tuning.

As mentioned, you'll also need supporting fueling mods like injectors, fuel pumps, and a tuner to get the most from an S400. Never skimp on tuning as it makes the turbo swap work safely and reliably.

S400 Turbo Tuning and Maintenance

Proper S400 Tuning

Tuning is absolutely crucial when upgrading to an S400 turbo on your 6.0L Powerstroke. The ECM needs to be properly calibrated for the larger turbocharger. A reputable custom tuner will optimize your truck for the S400 by adjusting fueling, boost levels, transmission tuning, and more. Expect to pay around $600-$800 for S400-specific custom tuning.

Maintenance and Longevity

One great thing about an S400 turbo upgrade is it actually improves the longevity of your 6.0L engine by reducing EGTs and stress. But you still need to stay on top of maintenance:

• Change oil every 5,000 miles or less
• Replace fuel filters frequently
• Clean intake side of turbo often
• Check for leaks around turbo and discharge pipe
• Monitor EGTs and boost levels

Follow these tips and your S400-equipped 6.0L Powerstroke will provide years and miles of unrelenting power!

Conclusion

Swapping to an S400 turbocharger is hands-down one of the best modifications you can make to a 6.0L Powerstroke. With supporting fuel and tuning upgrades, these trucks can produce 600hp+ to the wheels while also improving reliability. Just be sure to work with a reputable shop and tuner to ensure everything is done right.

So if you're lucky enough to own one of Ford's 6.0L Powerstrokes, treat it to an S400 turbo kit. Once you hear that sweet whistle under acceleration, you'll be reminded just how amazing these trucks can be. The S400 swap certainly isn't cheap, but it's worth every penny to maximize your truck's performance.

FAQs

How much power can I expect from an S400 turbo?

With supporting modifications, the S400 turbo can add 160-200 horsepower at the wheels safely on a 6.0L Powerstroke.

What fueling mods do I need with an S400 turbo?

Upgraded fuel injectors, fuel pump, and a custom tune are critical to get the most power from an S400 turbo kit.

Will an S400 turbo improve reliability?

Yes! The S400 flows better and reduces EGTs. This improves engine longevity when paired with proper maintenance.

What maintenance is needed for an S400 turbo?

Change oil frequently, replace fuel filters, clean intake side, check for leaks, monitor EGTs and boost - critical S400 maintenance.

Do I need a custom tune with an S400 turbo?

Absolutely! A proper S400-specific custom tune is vital for optimizing power gains and engine longevity.