The SPOOLOGIC Turbo Rebuild Kit SL-210-041 is a complete internal-parts service kit for rebuilding a genuine OEM HX35 / HX35W turbocharger on 1994-2002 5.9L Cummins applications. Built to OE specifications and sized to drop directly into the factory CHRA — the same internal wear parts SPOOLOGIC uses when building a new turbo on our SL-100 line. Every wear item that spins, seals, or supports the rotating assembly is included as a new part — extreme duty journal bearings and bearing spacer, 360° thrust bearing and thrust collars, step gap seal rings, snap rings, and O-rings. Ships as an internal-parts kit intended for professional rebuilders and experienced DIY builders who will disassemble the CHRA, replace all wear parts, and dynamically balance the rotating assembly on a VSR balancer before returning the turbo to service.

Common HX35 / HX35W Failure Symptoms This Kit Addresses

• Blue smoke on startup or under boost — worn compressor-side and turbine-side oil seals
• Excessive shaft play — failed or worn journal bearings and thrust bearing
• Oil in the intake tract or exhaust housing — seal ring wear or bearing housing scoring
• Slow spool or loss of boost — degraded rotating assembly clearances
• Whistling or grinding noise — bearing wear, contact between rotating and stationary parts
• High crankcase pressure or elevated oil consumption traced back to the turbo

Built to OE Spec — Same Premium Internals Used in SPOOLOGIC Turbos

This kit is designed to rebuild your genuine OEM HX35 / HX35W turbocharger. Every wear part is built to OE specifications and sized to drop directly into the factory CHRA — while using the same premium components SPOOLOGIC installs when building a new turbo on our SL-100 line. Extreme duty journal bearings are upgraded from standard OEM bearing material for better thermal tolerance and longer service life. The 360-degree thrust bearing replaces the OEM half-thrust design for improved axial load capacity under sustained boost. Step gap seal rings are precision-ground and sized for the HX35 / HX35W CHRA. Rebuild your OEM turbo to SPOOLOGIC internal spec — not OE-service-replacement spec.

What's Inside the Kit

• Extreme duty journal bearings & bearing spacer — upgraded bearing material for improved thermal tolerance and longer service life
• 360° thrust bearing & thrust collars — upgraded from OEM half-thrust design for better axial load capacity
• Step gap seal rings — compressor and turbine side, replacing worn OE seals for tight oil control
• Snap rings, retaining rings, and O-rings — all consumables required to reassemble the CHRA

What's Included

• 1 SPOOLOGIC turbo rebuild kit — all internal wear parts required to rebuild the CHRA (journal bearings, bearing spacer, 360-degree thrust bearing, thrust collars, step gap seal rings, snap rings, O-rings)

Features

• Complete internal-parts rebuild kit for the genuine OEM HX35 / HX35W turbocharger
• Built to OE specifications — drops directly into the factory CHRA
• Extreme duty journal bearings — upgraded material for improved thermal tolerance
• 360-degree thrust bearing — upgraded from OEM half-thrust design
• Compressor-side and turbine-side step gap seal rings for tight oil control
• Snap rings, retaining rings, and O-rings included
• Same premium internal components SPOOLOGIC uses when building a new turbo on our SL-100 line
• Built brand new, never remanufactured

Fits 1991.5-2002 5.9L Cummins

• 1991.5 – 2002 Dodge Ram 2500 / 3500 5.9L Cummins

Turbo Applications

• Replaces factory Holset HX35 (1994-1995 5.9L 12-Valve Cummins) — SL-100-072
• Replaces factory Holset HX35 (1996-1998 5.9L 12-Valve Cummins) — SL-100-073
• Replaces factory Holset HX35 (1998.5-2002 5.9L 24-Valve Cummins) — SL-100-074
• Replaces factory Holset HX35 (2000-2002 5.9L 24-Valve Cummins, automatic transmission applications) — SL-100-075
• Replaces factory Holset HX35 (1998.5-2002 5.9L 24-Valve Cummins) — Stock Plus billet upgrade — SL-100-076
• Replaces factory Holset HX35 (1994-2002 5.9L 12-Valve and 24-Valve Cummins) — Stage 1 billet upgrade — SL-100-077

Replaces Factory OEM Part Numbers

• 3539911
• 3539912
• R5010960AA
• 3534919
• 3539369
• 3539371
• 3539373
• 3802678
• R5010276AA
• R5010278AA
• 3592766
• 3592767
• 5017509AA
• R5017509AA
• 3596183
• 3596393
• 4036239
• 4089642
• R5017787AE
• BD1045758
• FPE-HX35-63-FMW

DIY Product — All Sales Final, No Warranty, No Returns

This SPOOLOGIC turbo rebuild kit is a professional DIY assembly product intended for experienced turbo builders and rebuild shops. Successful installation requires proper tools, OEM service procedures, cleanliness standards, correct CHRA disassembly and reassembly technique, and dynamic balancing of the completed rotating assembly on a VSR balancer before return to service. Because SPOOLOGIC has no control over installation quality, balancing accuracy, or the condition of the parts the kit is installed into, all sales are final — no warranty, no returns, no exchanges. By purchasing this kit you acknowledge that you are responsible for correct rebuild, balancing, and installation.