BD Diesel Exhaust Manifolds: Complete Guide for Cummins & Power Stroke

Everything you need to know about BD’s heavy-duty exhaust manifolds—why factory castings crack and warp, how BD fixes it with thicker high-silicon ductile iron and longer hardware, and which kit fits your 5.9L Cummins, 6.7L Cummins, or 6.7L Power Stroke.

Jump to: Why Manifolds Fail • The BD Difference • 5.9L Cummins • 6.7L Cummins (Pickup & Cab/Chassis) • 6.7L Power Stroke (2011–2019) • Compare Kits • Install & Torque • FAQs

Why Factory Manifolds Crack, Warp, and Leak

  • Thermal cycling & DPF regen heat (late-model): Repeated heat-soak and regeneration events grow/shrink the casting until it warps and the bolt/stud load drops, causing leaks.
  • Thin-wall castings: Many OE pieces trade mass for cost/weight, which accelerates distortion and gasket failure.
  • Short hardware & weak flanges: Shorter studs and thin flanges lose clamp load when hot; broken studs follow.
  • Age & vibration: High mileage, towing, and rough roads fatigue the manifold and hardware.

The BD Difference: Thick-Wall. Smart Hardware. Real Flow.

Core upgrades across BD’s diesel lineup
• High-silicon ductile iron castings built to survive extreme EGT and vibration
• Thicker walls and machined thicker flanges to fight warping and clamp-loss
• Longer studs + thick spacers to retain clamp load through heat cycles (black-oxide coated)
• Gasket-matched ports and CFD-driven runners for smoother flow and faster spool
• Full gasket & hardware kits for a one-and-done job

BD Exhaust Manifolds for 5.9L Cummins (1994–2007)

Cracked 5.9L manifolds and broken studs are legendary. BD’s high-silicon ductile iron replacements add mass and smarter hardware to keep clamp load when hot, reduce leaks, and stabilize drive pressure for consistent spool. Options cover 12-valve and 24-valve fitments and common turbo flange patterns (T3/T4). Pair with a BD Screamer or stock charger for a quiet, leak-free setup.

  • Thick-wall, CFD-tuned runners help equalize pulse energy for better turbine efficiency.
  • Longer studs + spacers reduce fastener stretch and gasket creep after heat soak.
  • Complete hardware & gaskets included on most kits for a clean install.

BD Exhaust Manifold Kits for 6.7L Cummins (2007.5–2018)

On the 6.7L, DPF regen temps and long grades can punish the OE casting. BD’s fully divided pulse manifold uses high-silicon ductile iron and a precision slip joint so the assembly can expand/contract without cracking. It’s fully EGR-compatible, includes new gaskets, grade 10.9 bolts, and spacers, and is pre-drilled for a pyrometer.

Shop 6.7L Cummins Manifolds:
• Pickup (2007.5–2018): Exhaust Manifold Kit — Note: not for sale on licensed California vehicles.
• Cab & Chassis (3500/4500/5500): Exhaust Manifold Kit — tailored ports & hardware for C&C packaging.
  • Why it lasts: thick-walled ductile iron + slip joint fights cyclic fatigue.
  • Why it performs: true pulse-divided runners preserve energy at the turbine for quicker response under tow.
  • What’s in the box: exhaust, EGR port, and turbo mount gaskets; long hardware; pyrometer port.

Certification notes: SEMA Certification No. SC-BDD01-0155; emissions sale restrictions apply (not for licensed CA vehicles).

BD Exhaust Manifolds for 6.7L Power Stroke (2011–2019)

Ford’s 6.7L (“Scorpion”) often sees warped flanges, broken studs, and cross-tube leaks. BD solves it with 0.275" thick-wall castings (≈75% thicker than OE), machined thicker flanges, and the longest stud & spacer kit spanning all 8 cylinders. Fully EGR-compatible and 50-STATE LEGAL via CARB EO, these kits also deliver real, measured flow gains.

  • 2011–2014 set: average flow increase ≈ 9.3% (OE ~173 cfm/port → BD ~189 cfm/port). View kit
  • 2015–2019 set: average flow increase ≈ 8.1% (OE ~169 cfm/port → BD ~174 cfm/port). M8 stud install tool included. View kit
  • Passenger/driver side singles also available for service jobs and MPD budget SXE turbo kit compatibility. ’11–’14 RH • ’15–’19 RH • ’11–’16 LH

Emissions: CARB EO D-553-17 • SEMA Certification No. SC-BDD01-0050.

Compare BD Diesel Exhaust Manifolds (At a Glance)

Platform Core Upgrades Emissions Notes Best For
5.9L Cummins (’94–’07) Thick-wall ductile iron, longer studs & spacers, CFD-tuned pulse runners; T3/T4 options Check kit by year; service parts (no tuning required) Cracked/warped OE, broken studs, tow reliability, stable spool
6.7L Cummins (’07.5–’18, Pickup & C&C) Divided pulse manifold, high-silicon ductile iron, slip joint, gaskets + grade 10.9 hardware, pyrometer port SEMA SC-BDD01-0155; not for sale on licensed CA vehicles Regen heat durability, leak-free towing, EGR compatibility
6.7L Power Stroke (’11–’19) 0.275" thick walls (~75% thicker), machined thicker flanges, longest stud & spacer kit, gasket-matched ports CARB EO D-553-17 (50-state legal); SEMA SC-BDD01-0050 Fix warped flanges & broken studs; measured flow gains (8–9.3%)

Install & Torque Tips (Read Before You Wrench)

  • Surface prep: Clean head ports & check with a straightedge. Replace any stretched/broken studs.
  • Gaskets & hardware: Use the included BD gaskets, long studs, and spacers; they’re part of the clamp-load strategy.
  • Tightening sequence: Work center-out in stages. Typical 6.7 Cummins torque is ~32 ft-lb (43 N·m)—always follow the exact spec/sequence in the BD install sheet.
  • Heat cycle & re-torque: After one full heat cycle, re-check fasteners. This locks in clamp load on the thicker flanges.
  • Pyro port: If equipped, install your probe with anti-seize; verify clearance to runners.

Who Should Upgrade?

  • Tow & work trucks: Hot-cold cycles and load make OE castings move. BD keeps them sealed.
  • High-mileage daily drivers: Prevent the “cold tick” and exhaust smell that hurts spool and MPG.
  • Performance builds: Stable pulse energy helps turbo efficiency—especially with drop-in BD Screamer turbos and tuned fueling.
Related BD Solutions
• 6.7L Cummins Manifold Kits: Pickup • Cab & Chassis
• 6.7L Power Stroke Sets: 2011–2014 • 2015–2019
• Passenger/Driver Singles: PS 6.7 RH ’11–’14 • PS 6.7 RH ’15–’19 • PS 6.7 LH ’11–’16

Frequently Asked Questions

Will a BD manifold add power?
The primary win is reliability—no leaks, no warping, stable drive pressure. That said, better pulse energy and port matching help spool and turbine efficiency, which you’ll feel as cleaner response and steadier EGT under load.

Are these 50-state legal?
6.7L Power Stroke kits: Yes—CARB EO D-553-17.
6.7L Cummins kits: Not for sale on licensed CA vehicles (see product page).
5.9L Cummins service manifolds generally do not require tuning—verify local rules.

Do I need to re-torque?
Yes. After one full heat cycle, re-check fasteners. The thicker flanges and longer studs are designed to settle and hold clamp load after heat.

What else should I replace while I’m in there?
Manifold gaskets (included on most kits), fasteners, cross-over tube gaskets (PS 6.7), and consider fresh turbo hardware. If you’re chasing EGT or spool, inspect the up-pipes/cross-over and charge plumbing.

BD Diesel Exhaust Manifold 5.9L Cummins 6.7L Cummins 6.7L Power Stroke Towing Reliability EGT Management