How Much Does It Cost to Bulletproof a 6.0 Powerstroke? (Updated Prices)

If you’re looking to bulletproof your 6.0 Powerstroke, you’re probably wondering how much it’s going to cost you. The answer? It depends on a variety of factors, including the parts and labor involved. But don’t worry, we’re here to break it down for you. 

Whether you’re a seasoned diesel enthusiast or a newcomer to the world of bulletproofing, we’ve got you covered with all the information you need to know.

How Much Does It Cost to Bulletproof a 6.0 Powerstroke?

Bulletproofing a 6.0-liter Ford engine involves replacing its original parts with more durable and optimized ones. The cost of this upgrade varies based on the quality of the parts and whether you choose to do the installation yourself or hire a professional. 

Generally, you can expect to spend anywhere from $4,000 to $9,000 to bulletproof your 6.0 Powerstroke engine. It’s important to note that investing in bulletproofing can help prevent costly engine repairs in the future, making it a smart long-term investment for diesel enthusiasts.

Why Should You Bulletproof Your 6.0 Powerstroke Engine?

Manage Your Engine’s Overheating Issues

If you frequently use your 6.0-liter engine for heavy-duty tasks like hauling, overheating can become a concern no matter how careful you are. To avoid potential engine damage and costly repairs, bulletproofing your engine becomes a necessary step. 

Opening the entire Unit

While the 6.0-liter engine is designed for heavy lifting, upgrading to more durable parts can ensure your engine can withstand the stress of daily use. Don’t risk engine failure, consider bulletproofing as a smart investment for the longevity of your engine.

Increasing Your Engine’s Durability

Bulletproofing your engine can provide several benefits, such as ensuring that all parts are functioning at their best. This upgrade helps minimize the risk of overheating, which can cause significant damage to your engine. By bulletproofing, you may extend the lifespan of your engine by several thousand miles, potentially saving you money on repairs in the long run. 

Additionally, you’ll have peace of mind knowing that your engine can handle heavy loads without breaking down or overheating.

Should All 6.0 Powerstroke Engines Be Bulletproof?

If you’re skeptical about the need for bulletproofing your 6.0 powerstroke engine or concerned about the cost, there are reasons to be cautious. While many 6.0 diesel engines are sold each year, they may only be partially faulty and have limitations in terms of performance. 

However, if you want to get the most out of your engine, bulletproofing can be a wise investment. For those on a budget or looking for a more moderate upgrade, focusing on essential components such as the Ford oil cooler and EGR cooler can still provide significant benefits. 

Taking care of the engine parts

But, if you want to push your engine to its limits, fully bulletproofing can provide added peace of mind and improved performance. Ultimately, the decision comes down to your needs and budget.

What Are the Essential Parts of Bulletproofing?

Water Cooler

The water cooler is an essential component in your engine’s dynamic system, responsible for cooling and moving coolant throughout the engine. To bulletproof your engine’s water cooler, you’ll need to allocate at least $400 for parts, and potentially more for installation. 

Upgrading the water cooler is a crucial step in bulletproofing your engine, as it can significantly improve its overall performance and reduce the risk of overheating.

Fuel Injection Control Module

The fuel injection control module (FICM) is a crucial regulator of your vehicle’s performance and fuel efficiency. If you’re looking to improve your vehicle’s overall mileage and achieve a smoother ride, investing in a new FICM is essential. While the cost may seem high, typically around $900, it’s a necessary expense that can provide significant benefits in the long run. 

The FICM controls the flow of fuel to your engine, ensuring optimal performance and fuel efficiency.

Reinstalling the body of the car

Gas Tank

When it comes to bulletproofing your engine, manufacturers typically recommend matching the gas tank with other upgraded components for optimal performance. While this can come at a significant cost of around $4,000, the benefits are worth considering. 

Upgrading your gas tank can lead to cooler engine temperatures and a longer-lasting EGR cooler, providing noticeable improvements to your vehicle’s performance and lifespan. For those living in colder climates, a bulletproof gas tank can be particularly beneficial, as it can help avoid issues with cold starts.

Oil Cooler

The oil cooler is a crucial component in your engine’s lifespan, responsible for ensuring consistent and steady-state temperature for the oil it supplies. Bulletproofing the oil cooler is a crucial step in protecting your engine and extending its lifespan. 

While the cost may seem high, at around $3,000 for the components and an additional $1,000 for installation, it’s an investment that can save you money in the long run. The oil cooler helps prevent overheating and other issues that can lead to costly repairs or even engine failure. 

Bulletproof Diesel

As such, it’s recommended that bulletproofing your oil cooler should be one of the first steps in the bulletproofing process.

Head Studs

If you’re looking to improve the performance and longevity of your engine, head studs are a must-have component. By enhancing your car’s head-and-block gripping force, head studs improve the strength and durability of your engine, allowing it to handle more demanding tasks without suffering damage. 

While the cost of head studs may seem steep, it’s important to remember that the investment is well worth it in terms of long-term performance and savings on costly repairs. The cost of head studs typically breaks down to around $600 for the components and $400 for installation, which reflects the significant effort required to ensure they’re properly bulletproofed.

How Can You know if a 6.0 is Bulletproof?

A bulletproofed 6.0 diesel engine is easy to distinguish from a standard engine by checking the engine’s components under the hood. A bulletproofed engine will have a water cooler, FICM system, gas tank, oil cooler, EGR cooler, and head studs that have been replaced with more durable and optimized parts. On the other hand, a standard engine will have original parts installed.

Internal Tubes model

How Long Does a Bulletproof 6.0 Powerstroke Last?

The lifespan of a 6.0 engine depends on how well it is maintained and cared for. One of the factors that contribute to its longevity is the use of high-quality engine oil. With proper care and maintenance, you can expect your 6.0 engine to provide you with at least 300,000 miles of service. 

However, it’s important to note that there are several factors that can affect the lifespan of your engine, such as how frequently it is used and the conditions in which it is operated.

Is Bulletproofing a 6.0 Powerstroke Engine Worth the Investment?

If you are looking for a more reliable and durable 6.0 powerstroke engine, bulletproofing is definitely worth it. But not everyone has the funds to completely overhaul the cooling system of their vehicle. If you are on a tight budget, you can still get some of the benefits of bulletproofing by focusing on the oil cooler and FICM. 

Fixing the car engines

These two components are important for engine performance and can make a significant difference in the lifespan of your engine. By choosing this option, you can enjoy a more budget-friendly but still reliable engine.


Bulletproofing a 6.0 Powerstroke engine can greatly improve its reliability and longevity. While it can be an expensive process, there are options for those on a budget, such as focusing on key components like the oil cooler and FICM. Ultimately, the decision to bulletproof your engine will depend on your individual needs and budget. 

Investing in a bulletproofed engine can save you money in the long run by reducing the need for costly repairs and increasing the lifespan of your vehicle.


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