How Much Does It Cost To Bulletproof A 6.0 Diesel?

The following are a few of the changes that many consider to be part of bulletproofing the 6.0L Power Stroke:

These are a handful of the 6.0L turbodiesel engine’s most problematic components. These are considered the key “bulletproof” things by some. Some people feel you should do all of the above, while others believe you should simply do a few of them. On the Ford 6.0 diesel, upgrading all five of the above elements might be quite pricey. Is it worthwhile to tackle them all? What enhancements should you forego?

Throughout the article, we’ll go through each of these upgrades and give our opinion on whether or not they’re good upgrades. We also mention a few more minor upgrades towards the end of the article for those who are interested. Let’s get started.

Ford 6.0 Oil Cooler “Bulletproof” Upgrade

The oil cooler on the 6.0 Power Stroke engine has the potential to trigger a series of breakdowns. The stock Ford oil cooler’s coolant tubes may become clogged. This depletes the EGR cooler’s oxygen supply, potentially causing it to overheat and fail. When the EGR cooler fails, coolant may leak into the intake, causing high pressures and lifting of the head. The point is that the Ford 6.0L diesel oil cooler is a major source of failure.

BulletProof Diesel oil cooler systems cost between $2,000 and $2,500. It is not a low-cost update. Regardless of the oil cooler issues, the EGR cooler is a troublesome region. As a result, even if you’re upgrading the 6.0 oil cooler, it’s still a good idea to do the EGR cooler.

Is the Ford 6.0 Oil Cooler Upgrade Worth It?

Unless you plan on keeping the Ford 6.0L for a long time, we recommend skipping the oil cooler addition. The installation can cost anywhere from $700 to $1,000, so the improvement could end up costing more than $3,000 in total. For approximately $300, you can get a factory Ford 6.0 Power Stroke oil cooler. When you consider in labor, you’ll need to replace the factory oil cooler around three times before the indestructible 6.0L oil cooler upgrade is worthwhile. Factory coolers typically last between 60,000 and 100,000 kilometers.

It’s still a fantastic update for added security. Those who intend to maintain their Ford for a long time should think about improving the oil cooler. Otherwise, just use OEM Ford parts to replace it.

L Power Stroke EGR Cooler Mod

The EGR cooler, as mentioned in the previous section, is prone to failure. Some Ford 6.0 diesel owners opt for an EGR deletion kit instead. You can get 6.0 EGR deletion kits for for $100, so it’s a good deal. However, there are various legal reasons why the EGR cooler should not be removed. With an EGR delete, you’ll almost certainly fail an emissions inspection. It will also cause a check engine light to illuminate, which must be removed by a tuner.

The Bulletproof 6.0 Power Stroke EGR cooler is here to help. This EGR modification should last the life of the 6.0 Power Stroke and save you the trouble of dealing with possible emission issues.

Is the 6.0L EGR Cooler Worth It?

Yes, we believe the Bulletproof Diesel EGR cooler modification is well worth the money. If your EGR fails and you require a replacement, we strongly advise you to upgrade. If emissions aren’t an issue, an EGR delete kit is also a viable choice.

PowerStroke 6.0 Water Pump Upgrade

Another typical issue with the Ford 6.0L Power Stroke diesel engine is water pumps. The water pump in the OEM Ford 6.0L has a plastic impeller that is prone to failure. When the coolant pump malfunctions, you’ll likely notice a pool under the truck. If coolant flow is interrupted, the 6.0 will immediately overheat.

BulletProof Diesel’s water pump modifications feature an aluminum impeller. The bearing assembly, seal, and housing are also upgraded. It effectively eliminates all of the locations on the factory 6.0 Power Stroke water pump that are prone to failure.

Should You Upgrade the 6.0 Power Stroke Water Pump?

If your Ford water pump is still working, we recommend skipping this update for the time being. However, if and when the water pump fails, the update is well worth it. $350 gets you the Bulletproof 6.0 Power Stroke water pumps. You should also consider their entire cooling system upgrade, which eliminates all of the 6.0L cooling system’s flaws.

Ford 6.0L FICM Bulletproofing

The Ford 6.0L Power Stroke fuel injectors are controlled by the Fuel Injection Control Module (FICM). The diesel engine will have problems starting or will not start at all if the FICMs are damaged. Rough idle, stuttering, and power loss are also common symptoms.

There are a few different alternatives to choose from. The power supply is frequently the cause of 6.0 FICM failures. Bulletproof and others, on the other hand, provide full upgrades for the FICM. This includes a new Ford OEM logic board and a power supply update.

Is the Ford 6.0L FICM Upgrade Worth It?

The Bulletproof 6.0 FICM option is a toss-up for us. The total cost of the upgrading is roughly $800-1050, so it isn’t cheap. Even the power source costs $500 on its own. The TechSmart FICM power supply with an OEM cover is our recommendation. It’s a much better deal at $230 that won’t break the bank.

Power Stroke “Bulletproof” Head Studs

Here we’re returning to the original topic of oil coolers. The 6.0 headlift isn’t caused by a manufacturing flaw in the head, gaskets, or head studs. Rather, the failure of the oil cooler set off a chain reaction. This causes the OEM 6.0L Power Stroke EGR cooler to fail, causing the head to elevate.

In this case, the head and head studs aren’t the issue. Upgrade to the bulletproof EGR cooler or remove it entirely. Head studs should not be an issue if this is done.

Are 6.0 Head Studs Worth It?

On the 6.0L diesel, skip the ARP head studs. The ARP studs cost roughly $500, but they require a lot of work. If you’re going to spend the money on the parts anyhow, it can’t harm to update to the 6.0 head studs. We’ll avoid this improvement if it’s not necessary.

How many miles will a Bulletproofed 6.0 last?

The Ford oil cooler will become clogged and eventually fail. However, with correct fluid changes, they will offer you a good 50,000-80,000 miles. A Ford oil cooler costs $300, with labor costing $800 for ten hours. Needless to say, one Bulletproof oil cooler can replace a lot of Ford oil coolers. You’re unlikely to own the truck long enough to be concerned about the next cooler.

Skip the head studs

The purpose of head studs is to increase the clamping force between the head and the block. This upgrade is essential for high-boosted applications. However, we’ve never encountered poor Ford heads as a result of insufficient clamping force in factory settings. It’s almost always the result of a series of failures or partial failures in the EGR.

Bulletproof FICM can be problematic.

Poor solider is used by the OEM Ford FICM. Resistors loosen over time, creating irregular engine behavior. The Bulletproof FICM is a good product, but the increased voltage necessitates the use of a tuner to avoid overvoltage engine codes. We propose a tech smart replacement board unless you’re trying to improve performance. They cost $150.

What does it take to BulletProof a 6.0 Powerstroke?

BulletProof Diesel defines a 6.0L Power Stroke as “bulletproofed” when at least four of the five major problem areas have been solved. Oil cooler, EGR cooler, head studs, fuel injection control module (FICM), and water pump are the five sections.

How much does Bulletproofing cost?

The price can differ by up to 30% from usual pricing. The cost of only the doors and windows can range from $18,000 to $45,000. Bulletproofing a vehicle might cost up to $100,000 in total.

Is Bulletproofing a 6.0 Necessary?

More information can be found here. Again, unless four of the five pattern failures are corrected with authentic Bullet Proof Diesel parts, a 6.0L is not a “Bullet Proof Diesel” engine. This includes the FICM module, EGR cooler, and water pump, as well as the problematic OEM oil cooler.

What powerstroke to avoid?

The 6.0L Powerstroke is a well-known engine. Because of the engine’s poor performance, Ford and Powerstroke’s parent company, Navistar, were involved in a lengthy court dispute. Ford said Navistar produced a faulty engine. Ford has ignored unsatisfactory test results for the 6.0L Powerstroke, which could have prevented post-production issues, according to evidence.

As the Powerstroke suffered catastrophic failures, expensive engine replacement warranty claims flooded in. The cab of the vehicle had to be removed for the majority of these repairs. Because to this engine, many owners have lost faith in the brand. A series of recalls affecting this notoriously problematic truck are listed by Consumer Reports.

Do all Ford 6.0 diesels have problems?

If you’re a diesel enthusiast like myself, you’re probably aware that most people will avoid purchasing a Ford Superduty Diesel truck from the 2003 to 2007 model years. The 6.0L Powerstroke is notorious for its issues. The majority of these issues stem from manufacturing design. The 6.0’s frequent troubles are largely due to the new EGR emissions technology, which was designed to meet emissions rules at the time. Because head studs provide insufficient gripping force, blown head gaskets are common. HPOP failure, injector stiction, FICM failure, and clogged oil coolers are some of the other 6.0L Powerstroke issues. Fortunately, once these issues are resolved, the trucks become far more dependable. Some of these issues are avoidable. However, if you stick to a tight 6.0L Powerstroke Service Schedule, you can substantially limit the number of issues you have.

How much does it cost to delete a 6.0 Powerstroke?

The recirculation of exhaust gas is one of the ways that a vehicle derives its power. The additional air enters the combustion chamber to provide a more explosive outcome, which might result in improved acceleration. If you have a 6.0 Powerstroke engine, an EGR delete can disrupt this process by allowing colder air to pass through. Because you’re eliminating exhaust gas recirculation to offer a more robust experience, that conclusion is conceivable.

Most diesel engines, including the 6.0L Power Stroke engine found in vintage Ford vehicles, can be fitted with an EGR deletion kit. Since 1994, this moniker has been applied to all diesel engines produced by Ford Motor Company in their line of cars.

If your car has a 6.0 Power Stroke engine and you’re looking for a solution to improve its performance profile, these are the benefits and drawbacks of using an EGR deletion in your configuration.

List of the Pros of a 6.0 Powerstroke EGR Delete

1. It’s a Ford product designed for the 6.0L Power Stroke engine.

The design of most EGR deletion kits for diesel engines is a generic option that can be used with practically any product. When you buy a 6.0 Power Stroke EGR delete for your Ford, you’re getting something that’s designed to operate with your engine’s EGR valve. Even with advancements in diesel fuel and engine construction over the last decade, the valve can accumulate a lot of soot over time. When this happens, the engine does not receive enough air.

With a high soot percentage and an EGR valve, there’s a chance that part (or all) of that deposit will end up in the combustion chain. This valve will be bypassed if you install an EGR delete for your 6.0L Power Stroke engine. The result is a rapid restoration of power and performance, similar to what you’d get when you initially drove it home.

2. After installing the EGR Delete, Ford automobiles receive higher gas mileage.

When you install an EGR delete on your 6.0L Power Stroke engine, you will also be restoring your vehicle’s original fuel economy standards. This option allows you to guide the exhaust stream away from the engine rather than toward it. That means you’ll have cleaner operations while driving or idling, minimizing the amount of effort your particulate filter has to do to keep the engine running.

A Ford vehicle’s fuel economy can improve by up to 20% after adding an EGR delete, depending on how much soot is currently affecting the EGR valve. Simultaneously, you’re promoting a healthier engine that will run even longer.

3. The temperature of the engine will drop noticeably.

There will be a noticeable reduction in operating temperature once you have an EGR delete installed on your 6.0L Power Stroke engine. There are two reasons for this advantage. First, the exhaust gases are diverted away from the combustion process, allowing cooler air to flow toward the engine. You’re also avoiding a potentially clogged valve, which implies reduced friction in the air flow chain.

Because this method decreases the amount of effort your coolant has to do to keep your engine at operating temperatures, the overall system is less stressed. It adds another layer of durability to your engine to consider.

4. It’s something you can utilize even if your Power Stroke engine has been modified.

Based on their driving habits or circumstances, Ford owners will sometimes adjust the settings of their 6.0L Power Stroke engine to maximize its power benefits. With most engines, once you’ve installed upgrades, adding more items beneath the hood to improve the vehicle’s performance becomes difficult. In this scenario, that is not the case with an EGR deletion.

Some owners may experience clogs elsewhere in the system, but most find that the 6.0L Power Stroke engine EGR delete solves their performance difficulties by bypassing the design’s most major soot issue. With mods in place, you get the same fuel efficiency benefits.

5. The majority of Ford owners can afford an EGR deletion for their engine.

In most places, an EGR delete kit for a Ford 6.0 diesel will cost around $329 before work. This option is available for a similar price on the internet. If you plan on conducting the work yourself, a basic set of tools will suffice to complete the task, which should take no more than a couple of hours. As a rough estimate, plan to add additional 50% to the total price if you want someone to install this option on your Ford vehicle.

6. You don’t need a kit to do an impromptu EGR deletion.

During the tuning procedure on a Ford car, you can turn off the EGR valve on your 6.0L Power Stroke engine. This benefit allows you to enjoy the benefits of the switch without ever having to unplug it, which makes your job a lot easier. Because the engine is doing the work for you, you will have a lower probability of an issue developing following the adjustment.

Instead of a full delete, some people refer to this benefit as an EGR disable. Whatever your personal choice may be, there is no disputing that it works.

List of the Cons of a 6.0 Powerstroke EGR Delete

1. If you remove the EGR valve from your 6.0L Power Stroke engine, the temperature of the exhaust gas will rise.

The exhaust fumes from a normal 6.0L Power Stroke engine are recirculated through the system to increase the vehicle’s overall efficiency. The exhaust gas is cooled in this procedure so that it can be used in the combustion chain. Because you’ve bypassed the EGR valve, which aids in this process, the exhaust gas temperature has risen noticeably, potentially affecting your performance.

It’s not uncommon for exhaust gas to remain in the engine, which means you’ll have to deal with two troubles as a result of this disadvantage. Because the circulation mechanism is inefficient, your oil may foul, and the engine may run hotter rather than colder. That is why, instead of an EGR deletion, some Ford owners choose to repair the damaged valve.

2. It’s possible that it’s illegal in your area.

The installation of an EGR delete on a 6.0L Power Stroke engine – or any other diesel engine, for that matter – is illegal in the United States. Every vehicle must comply with or exceed the government’s current emissions regulations. If your Ford truck is inspected and a kit is found, the fines for your modification could be thousands of dollars. The fact that you are no longer filtering particles from your system as it functions makes this option illegal to employ. Even though you get more power and acceleration with it on, your vehicle pollutes more.

3. With this engine type, an EGR deletion will not cure all performance difficulties.

A deletion kit will not address your problem if your EGR valve is locked in the open position due to the way soot collects in your system. When a system is held in this manner, the engine may start to struggle throughout the startup phase. There could also be a lack of engagement during idle time. If you’re only experiencing performance concerns at low speeds or while stopped, an EGR delete kit for a 6.0L Power Stroke engine won’t help.

4. Any impromptu emissions tests will fail you.

Although it is not as common as it once was, your car will fail any on-the-spot emissions tests if it is equipped with an EGR deletion. You may theoretically remove it for the investigation and then reinstall it thereafter if you have a planned inspection as part of your renewal. Because of the emphasis on low-emission designs, many of these programs are coming to an end, thus it may be a moot argument.

On January 1, 2020, the state of Washington will cease its complete emission check program, which means that no vehicles (including diesels) will be required to undergo testing before their registration is renewed.

5. It has the potential to lower your overall horsepower rating.

The EGR deletion kit is often more effective with older diesel engines, such as the 6.0L Power Stroke. Some designs may suffer with this choice since it limits the quantity of air available for the combustion chain, lowering the horsepower available in everyday operation. As a result, speaking with someone who is knowledgeable with Ford automobiles before installing this option may be required to ensure that this disadvantage does not impair your ability to drive in specific scenarios.

6. This feature may or may not be required for your car.

When you put an EGR deletion kit on a 6.0L Power Stroke engine, you get the same result as if the valve was entirely blocked. If you are unsure of the cost for your Ford vehicle, you can keep the valve and let it gather soot like arteries build plaque. Once enough bad things has passed through, a blockage will build, which will boost your performance.

Because the soot can still be dislodged, it’s normally best to install the deletion kit first, then clean out the blockage to optimize performance.

7. It may induce knocking in some Power Stroke engines.

The EGR deletion kit is well-known for causing the check engine light to illuminate on your dashboard’s HUD. It’s pretty uncommon for the engine to start knocking after the mod is finished. This occurs as a result of altering your vehicle’s temperature profile under the hood. If you’re using an inferior oil at the same time, your engine’s condition will quickly deteriorate. Because of this upgrade, several owners have reported that their engine’s total lifespan has been reduced.

When weighing the benefits and drawbacks of an EGR delete for a 6.0L Power Stroke engine, don’t forget to factor in the cost of the valve. The cost of replacing the EGR valve is about the same as installing the deletion kit. Based on your driving patterns and circumstances, this option may be advantageous in some cases, but it may not be the all-in-one answer that is frequently marketed.