Detroit Diesel Series 60 Performance Upgrades
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Detroit Series 60 PDI Big Boss Performance Upgrades
More Power. Better Fuel Economy. Greater Reliability. Discover why owner-operators across North America trust the PDI Big Boss system to unlock the full potential of their Detroit Diesel Series 60 engines.
Why Upgrade Your Detroit Series 60?
The Detroit Diesel Series 60 is one of the most reliable heavy-duty engines ever built, but many trucks are still running factory components that limit performance and efficiency. The PDI Big Boss upgrade system combines a performance exhaust manifold, upgraded turbocharger, and handheld tuner to deliver measurable gains in horsepower, torque, fuel economy, and overall drivability.
Owner-operators can expect up to a 10–15% increase in horsepower and torque while potentially reducing fuel costs by hundreds of dollars per month.
What's Included in the PDI Big Boss Package?
1. Ceramic-Coated Performance Exhaust Manifold
- Up to 20% increase in airflow compared to stock manifolds
- Reduces exhaust temperatures by approximately 75–100°F
- Improves throttle response and minimizes turbo lag
- Cast design eliminates common weld cracking issues
Why It Matters
Factory manifolds often restrict exhaust flow and are prone to cracking from repeated heat cycles. The PDI Big Boss manifold improves exhaust velocity, helps maintain optimal exhaust-to-boost pressure ratios, and contributes to lower exhaust gas temperatures (EGTs), resulting in improved efficiency and reliability.
2. PDI Big Boss Turbocharger (Stage 1 or Stage 2)
- Billet compressor wheel for durability and airflow
- 360-degree thrust bearing for increased reliability
- Stainless steel turbine housing for superior heat resistance
- Supports approximately 600–750 horsepower applications
- Optimized 1.32–1.45 A/R ratio for efficient drive pressure
Stage 1 vs Stage 2
- Stage 1: Designed for 12.7L non-EGR Detroit Series 60 engines
- Stage 2: Designed for 14L EGR Detroit Series 60 engines and required when tuning EGR applications
Why It Matters
The stock turbocharger becomes a restriction as fuel demand increases. The Big Boss Turbo improves boost response, lowers exhaust temperatures, reduces lag, and delivers stronger pulling power under heavy loads.
3. PDI Big Boss Tuner
- 10–15% horsepower and torque increase
- Potential fuel savings of $350–$800 per month*
- Economy Tune (+10%) and Power Tune (+15%) options
- Reads and clears diagnostic trouble codes (DTCs)
- Adjusts speed limiter, gear ratios, cruise control, and engine brake settings
- WiFi updatable software
- Custom gauge monitoring for boost, EGT, coolant temperature, oil pressure, rail pressure, RPM, and vehicle speed
- CARB-approved and designed to maintain OEM compliance
Why It Matters
The Big Boss Tuner isn't simply a horsepower device. It optimizes fuel delivery, improves engine efficiency, provides valuable monitoring capabilities, and allows drivers to customize operational settings for their specific applications.
Why Owner-Operators Choose the PDI Big Boss System
| Benefit | Real-World Impact |
|---|---|
| More Horsepower & Torque | Improved pulling power on grades and under heavy loads |
| Better Fuel Economy | Potential savings of $4,200–$9,600 annually |
| Cooler Exhaust Temperatures | Reduced wear on turbochargers and engine components |
| Reduced Turbo Lag | Smoother acceleration and improved drivability |
| CARB Compliant | Legal for use in California and all 50 states |
| Easy Installation | Plug-and-play tuner with bolt-on hardware upgrades |
Typical Investment
| Component | Typical Price Range |
|---|---|
| PDI Big Boss Ceramic-Coated Manifold | ~$1,450 |
| PDI Big Boss Stage 1 Turbo | ~$1,495 |
| PDI Big Boss Stage 2 Turbo | ~$2,450 |
| PDI Big Boss Tuner | ~$2,150 |
| Complete Stage 1 Package | ~$5,100–$5,500 |
| Complete Stage 2 Package | ~$6,100–$7,100 |
With potential monthly fuel savings ranging from $350 to $800, many owner-operators recover their investment within approximately 6–18 months.
Final Thoughts
If you're running a Detroit Series 60 and putting serious miles on your truck, the PDI Big Boss system is one of the most effective upgrades available. The manifold, turbocharger, and tuner work together to improve power, efficiency, and long-term reliability.
For owner-operators, every gallon of fuel matters. That's why the PDI Big Boss system continues to be one of the most popular Detroit Series 60 performance upgrades on the market.
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