How Much Does it Cost to Bulletproof a 6.0 Engine? Find the Affordable Solution Here!

In this article, we give you a straight answer to the question: how much does it cost to bulletproof a 6.0 engine?

If you own a 6.0 Powerstroke engine, you might have considered bulletproofing it to enhance its performance and reliability.

The process involves upgrading and fortifying various components, ensuring long-lasting durability.

The cost of bulletproofing a 6.0 can vary greatly depending on the upgrades you choose, ranging anywhere from around $3,000 to $8,000.

Some essential components to upgrade include the water pump system, oil and EGR coolers, and oil cooler.

Remember, investing in bulletproofing your 6.0 Powerstroke can ultimately save you from extensive repair costs down the road.

How Much Does it Cost to Bulletproof a 6.0


What Owners Should Know About Bulletproofing a 6.0

Benefits of Bulletproofing

Bulletproofing a Ford 6.0 engine enhances its durability and reliability. This can help your vehicle withstand heavy use and extreme conditions.

Bulletproofing involves replacing or upgrading multiple parts and systems within the engine, resulting in a better overall driving experience.

Reliability and Durability

By upgrading components like the oil and EGR coolers, water pumps, and fuel injectors, bulletproofing significantly extends the life of a 6.0 engine.

A bulletproof engine is less likely to fail or require major repairs, which can save you a lot of time and money in the long run.

Performance and Power

In addition to improved reliability, bulletproofing your Ford 6.0 engine can also enhance its performance and power.

By replacing or upgrading parts like the turbocharger, air intake, or exhaust system, you can get more horsepower and increased engine efficiency.

How Much Does it Cost to Bulletproof a 6.0


Common Challenges in Bulletproofing a 6.0 Powerstroke

Bulletproofing a 6.0 Powerstroke engine comes with its own set of challenges that owners should be aware of. Some of these challenges include addressing model-specific pattern failures and identifying potential issues that may arise during the upgrade process.

It is crucial to understand the common challenges associated with bulletproofing to ensure a successful and effective upgrade.

When considering bulletproofing, it is important to address model-specific pattern failures that are commonly observed in the 6.0 Powerstroke.

For example, the factory oil cooler in the 6.0 Powerstroke is prone to clogging, leading to overheating issues. To overcome this challenge, installing a more robust aftermarket oil cooler is recommended to prevent clogging and ensure proper cooling.

Major Components to Bulletproof a 6.0

Head Studs and Gaskets

One of the essential upgrades for bulletproofing a 6.0 Powerstroke engine is replacing the factory head bolts with stronger head studs.

This prevents common issues like blown head gaskets. ARP head studs are a popular choice for this task. Typically, expect to pay about $450 for a quality set of head studs.

Another critical component is the head gasket. To ensure longevity and proper sealing, choose quality gaskets like those from Fel-Pro or Victor Reinz. Gaskets’ costs can range from $150 to $300, depending on the brand and materials.

Oil Cooler Upgrade

The 6.0 Powerstroke’s factory oil cooler is prone to clogging and failure. An upgraded oil cooler maintains optimal oil temperature and ensures the engine remains cool.

Bulletproof Diesel offers a popular oil cooler upgrade kit that costs around $1,850. Labor for installation could run between $700 and $1,000.

EGR Cooler and Delete

The Exhaust Gas Recirculation (EGR) system is another common issue with 6.0 Powerstroke engines.

Upgrading the EGR cooler prevents issues like head gasket failure and coolant leakage. A reliable aftermarket EGR cooler upgrade ranges in price from $180 to $500, based on design and quality.

Some owners may choose to delete the EGR system entirely. This process involves removing the EGR cooler and disabling its function within the engine management system. Be careful, as EGR delete could cause emissions or legality issues in some areas.

How Much Does it Cost to Bulletproof a 6.0


Fuel Injection Control Module (FICM)

The Fuel Injection Control Module (FICM) controls the fuel injection system for the 6.0 Powerstroke engine.

A weak or failing FICM could cause reduced engine performance, hard starts, or even complete failure. Upgraded FICM units can cost between $500 and $1,000, adding reliability and improved performance.

Costs Involved in Bulletproofing a 6.0

Parts and Upgrades Costs

Bulletproofing a 6.0 Ford engine involves several aftermarket components and upgrade expenses.

The average cost of parts for bulletproofing ranges from $3500 to $5600. The list of essential parts includes an oil cooler, water pump, and EGR equipment.

Labor Costs and Mechanic Selection

Labor costs for bulletproofing a 6.0 can be substantial too. Expert mechanics typically charge anywhere between $8000 and $13000, including parts and labor, depending on your region and the depth of the desired upgrades.

When selecting a mechanic, look for someone with experience in bulletproofing, especially with 6.0 Ford engines.

Maintenance and Longevity

Once bulletproofed, your 6.0 Ford engine will have a longer lifespan and improved overall performance. However, maintenance is still necessary to ensure lasting results.

Regular oil changes, coolant system checkups, and tune-ups will contribute to the longevity of your 6.0 engine.

Following these basic maintenance practices will help you save costs by avoiding potential mechanical issues down the line.

Bulletproofing Considerations

Model-specific Issues and Solutions

When considering bulletproofing a 6.0 Ford truck, it’s essential to address model-specific pattern failures. For instance, the 6.0 is known for oil cooler problems, which can lead to overheating.

To resolve this issue, install a more robust and efficient aftermarket oil cooler. This will prevent clogging and ensure proper cooling.

It’s also crucial to consider the purchase of a truck with newer models, like the 6.7, which typically resolves some of these issues.

Towing and Mileage Impact

Bulletproofing a 6.0 also has an impact on towing and mileage. Upgrading exhaust gas recirculation (EGR) and oil coolers can improve the engine’s performance, resulting in more reliable and efficient towing capabilities.

However, it’s important to note that some upgrades may slightly affect fuel efficiency.

Cooling System and Overheating Prevention

A crucial aspect of bulletproofing is improving the cooling system to prevent overheating. Installing a more reliable water pump, in addition to upgrading the oil cooler, can significantly improve the cooling performance.

Ensuring that coolant hoses are in excellent condition and using a proper coolant mix can prevent future issues.

How Much Does it Cost to Bulletproof a 6.0


Alternatives To Look Out For

Aftermarket Parts and Benefits

Upgrading your 6.0 Powerstroke with various aftermarket parts can be a great alternative to bulletproofing.

Many of these parts are from reputable suppliers like Bulletproof Diesel. These aftermarket parts can improve performance, reliability, and fuel efficiency. For example, you can integrate parts like:

  • Upgraded fuel injectors
  • High-flow turbochargers
  • Performance exhaust systems

When considering aftermarket parts, it’s important to research and select quality components.

6.7 Powerstroke vs. Bulletproofed 6.0

An alternative to bulletproofing your 6.0 Powerstroke could be investing in a newer 6.7 Powerstroke engine.

While the initial investment may be higher, the 6.7 Powerstroke has a reputation for improved reliability and performance compared to the 6.0 Powerstroke. Some key advantages of the 6.7 Powerstroke include:

  • Higher torque and horsepower
  • Enhanced fuel efficiency
  • Improved emissions control

However, it is essential to understand your specific needs and budget before deciding between a bulletproofed 6.0 or upgrading to a 6.7 Powerstroke.


Bulletproofing a 6.0 Powerstroke engine is a viable option to enhance its performance and reliability. By upgrading essential components and addressing model-specific issues, owners can enjoy increased durability and improved power.

However, it’s crucial to carefully consider the costs, maintenance requirements, and alternatives like upgrading to a 6.7 Powerstroke. Whether you choose to bulletproof or upgrade, both the options can deliver an enjoyable driving experience.

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Sean Mendez

Hi, I am Sean, a self-confessed petrolhead. I live in Boise, Idaho with a busy family of four and our energetic Labrador retriever. Thank you for visiting my website. You can find my email on the contact page.

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