Your browser is too old for this website. 😢
We use modern layout techniques that are not compatible with your browser. Please consider upgrading browsers.
We recommend Download Chrome

What is a Bulletproof 6.0L Powerstroke Ford Diesel Kit?

Dennis Walsh on November 12, 2019

You may have heard of a “Bulletproof 6.0 powerstroke diesel kit”, but what is it? Unfortunately “Bulletproof” is ambiguous with no clear definition. In this blog, we’ll cover the bases, straighten out “Bulletproof”, and give our recommendations for a reliable Powerstroke 6.0 Ford Diesel.

Where “Bulletproof” originates

Bulletproof originates from Bulletproof Diesel, a parts and service shop in Mesa, Arizona. Bulletproof Diesel became famous making aftermarket EGR (Exhaust Gas Recirculation) coolers for Powerstroke 6.0L Diesels. They’ve since added aftermarket oil coolers, fuel injection control modules (FICMs), water pumps, and other aftermarket parts.

But quickly Bulletproof Diesel lost control of their branding and “Bulletproof” generically referred to an upgraded 6.0 engine kit, often consisting of a built motor.

The 6.0L Backstory — What went wrong at Ford

2003-2007 Ford 6.0L diesel engines have a bad reputation. Many early customers suffered blown head gaskets and sought Ford’s help under warranty. Ford dealerships replaced the head gaskets only to have the engines melt down again. The “6.0Ls are junk” myth began.

When Ford engineers took a step back, they realized the head gaskets were simply the breaking point in a chain of failures that started back with the oil cooler. Ford built the factory oil cooler with very small channels. The smaller the channels, the more cooling capacity with a similarly high propensity to clog. As particulates built up from the sand-casted parts, coolant passages block in the oil cooler.

That blockage starves the EGR cooler. The EGR cooler chills hot exhaust gases, but when water doesn’t reach the cooler from clogged upstream channels, it quickly overheats. The overheating EGR breaks apart and dumps coolant into the intake.

For the final straw, the cylinder head pressure with the additional water is so high that the cylinder heads float and the head gasket is destroyed.

Why the confusion

“Bulletproof” took on a life of its own on internet forums. The internet forum intelligencia claims to have “Bulletproof” definitions, but they are all varied. (We stay away from using “Bulletproof” or “Bulletproofed” at all.)

Bulletproof Diesel’s latest definition is to replace 4 out of 5 of the following…

  • Bulletproof Remote Oil Cooler
  • Bulletproof EGR Cooler
  • Bulletproof Water Pump
  • Bulletproof FICM
  • ARP Head Studs

But in our opinion, this feels more like marketing than solid advice. (So we can pick a $300 water pump over $3500 head studs and it’s “Bulletproof” just the same?)

We recommend the Bulletproof Diesel Stage 1 — new Ford oil cooler and Bulletproof EGR cooler.

We’ve owned and sold almost 1000 6.0 Ford diesels. From our years of experience, here’s our recommendation: Get the Bulletproof EGR cooler and Ford oil cooler. Here’s why.

Bulletproof Oil Cooler is a ton of money.

Bulletproof Diesel insists on their oil cooler. They say it lowers temperatures and prevents premature failures of the EGR cooler and injectors. And they’re right. But those benefits come in around $3000-$3500 installed!

The Ford oil cooler will plug and break. But they will give you a solid 50,000-80,000 miles, especially with proper fluid changes. A Ford oil cooler is ~$300 and labor at 10 hours is ~$800. Needless to say, you can do a lot of Ford oil cooler changes for one Bulletproof oil cooler. Odds are you won’t own the truck long enough to worry about the next cooler.

Skip the head studs

Head studs simply put more clamping force between the head and the block. For high boosted applications, this upgrade is required. But for factory settings, we’ve never seen bad Ford heads as a result of insufficient clamping force.

Bulletproof FICM can be problematic.

The factory Ford FICM uses poor solider on the board. Over time, resistors shake loose causing erratic engine behavior. The Bulletproof FICM is a quality piece, but the upgraded voltage requires a tuner to prevent over voltage engine codes. Unless you’re looking to upgrade the performance, we recommend a tech smart replacement board. They’re ~$150.

Bulletproof Water Pump is great when the stock one fails

You’ll typically find a failed water pump from the puddle of water under your truck. We like the Bulletproof water pump for a replacement, but we don’t proactively replace factory.

Our Bulletproof Stage 1: $2900 when purchasing a truck.

We recommend using our $2900 stage 1 Bulletproof install package at the time of purchase. Most shops charge $5500 for the same package, but we are interested in moving vehicles and offer it as an incentive to move vehicles. We are a Bulletproof Diesel authorized installer. (We aren’t on their website because we’re not an open to the public service shop, but you can call them to verify)

If you have any questions, please reach out on the chat to the right. One of our Bulletproof Diesel certified mechanics typically answer in minutes!

Looking for a Bulletproof 6.0L?

Our 6.0s either have Bulletproof parts, as shown in the options section, or you can add the stage one Bulletproof Powerstroke 6.0 kit for $2900 at purchase!

switch-check
switch-x
switch-check
switch-x
switch-check
switch-x
0 Offers
2004 Ford F350 Lariat
175,272 miles
4x4
Diesel
New Inventory 🔥
$11,300
3 Offers
2014 RAM 3500 Tradesman
153,287 miles
4x4
Diesel
$22,700
7 Offers
2002 Ford F250 Lariat
255,909 miles
4x4
Diesel
Sale Pending 🤞
$10,800
0 Offers
2011 Ford F250 Lariat
174,986 miles
4x4
Diesel
Lower Price 🏷
$21,900
3 Offers
2012 RAM 3500 Laramie
179,298 miles
4x4
Diesel
$27,600
0 Offers
2001 Ford F250 XL
119,760 miles
Lower Price 🏷
$4,900
2 Offers
2011 Ford F350 Lariat
141,744 miles
4x4
Diesel
Sale Pending 🤞
$26,400
3 Offers
2011 RAM 2500 Laramie
161,994 miles
4x4
Diesel
Lower Price 🏷
$24,400
1 Offer
2005 Ford F350 Lariat
158,433 miles
4x4
Diesel
Lower Price 🏷
$10,700
1 Offer
2011 Ford F250 Lariat
164,069 miles
4x4
Diesel
$22,400
6 Offers
2015 Ford F350 XL
144,990 miles
4x4
Diesel
$20,800
6 Offers
2007 Dodge Ram 2500 Laramie 5.9L
104,256 miles
4x4
Diesel
Lower Price 🏷
$21,300
3 Offers
2004 Ford F350 King Ranch
187,431 miles
4x4
Diesel
Lower Price 🏷
$13,200
1 Offer
2007 Ford F350 Bulletproof EGR Lariat
44,866 miles
4x4
Diesel
Lower Price 🏷
$24,900
3 Offers
2007 Dodge Ram SLT Mega Cab
209,106 miles
4x4
Diesel
Lower Price 🏷
$15,800
2 Offers
2012 Ford F350 King Ranch
188,041 miles
4x4
Diesel
$23,700
4 Offers
2003 Ford F350 Lariat
123,679 miles
4x4
Diesel
Lower Price 🏷
$10,300
1 Offer
2003 Ford F350 ARP Head Studs
185,101 miles
4x4
Diesel
Sale Pending 🤞
$12,600
1 Offer
2015 Ford F150 Lariat FX4
44,582 miles
4x4
$29,900
8 Offers
2005 Ford F350 Lariat
77,403 miles
4x4
Diesel
Lower Price 🏷
$19,900
1 Offer
2012 Ford F250 XL
150,385 miles
4x4
Diesel
$18,600
3 Offers
2007 Ford F250 XLT
188,677 miles
4x4
Diesel
Lower Price 🏷
$9,900
0 Offers
2007 Ford F250 XLT
79,977 miles
4x4
Diesel
Lower Price 🏷
$16,750
2 Offers
2006 Ford F150 Lariat
150,843 miles
4x4
Sold! Thanks Scott in TX ❤️
$6,800
1 Offer
2004 Ford F250 Lariat
147,239 miles
Diesel
Sold! Thanks David in AZ ❤️
$9,800
7 Offers
2006 Ford F250 XLT Manual
152,546 miles
4x4
Diesel
Sold! ❤️
$10,800
5 Offers
2001 Ford F250 Lariat
135,285 miles
4x4
Diesel
Sold! Thanks Brandon in AZ ❤️
$16,800
2 Offers
2006 Ford F250 Lariat
239,020 miles
4x4
Diesel
Sold! Thanks daniel in AZ ❤️
$9,900
4 Offers
2002 Ford F250 XLT
230,010 miles
4x4
Diesel
Sold! Thanks Jason in NV ❤️
$10,300
1 Offer
2004 Ford F350 Lariat Bulletproof EGR
89,112 miles
4x4
Diesel
Sold! Thanks Sonya in CA ❤️
$16,650
2 Offers
2006 Ford F250 Work Truck
151,371 miles
Diesel
Sold! ❤️
$7,800
1 Offer
2003 Ford F350 7.3L Lariat
171,535 miles
4x4
Diesel
Sold! Thanks Daniel in AZ ❤️
$11,600
6 Offers
2007 Ford F250 Lariat
148,269 miles
4x4
Diesel
Sold! Thanks Thom in CA ❤️
$14,850
1 Offer
2002 Ford F250 XLT
175,568 miles
4x4
Diesel
Sold! Thanks Matthew in AZ ❤️
$11,400
6 Offers
2005 Ford F350 XLT Bulletproof EGR
39,645 miles
4x4
Diesel
Sold! Thanks Erika in AZ ❤️
$18,600
3 Offers
2005 Ford F350 Harley Davidson
177,970 miles
4x4
Diesel
Sold! Thanks Boomer in AZ ❤️
$12,700
1 Offer
2004 Ford F350 Lariat
178,685 miles
4x4
Diesel
Sold! Thanks Robert in AZ ❤️
$11,600
8 Offers
2006 Ford F350 Lariat
72,746 miles
4x4
Diesel
Sold! ❤️
$20,600
2 Offers
2005 Ford Explorer XLT
95,189 miles
4x4
Sold! Thanks Diana in AZ ❤️
$4,400
1 Offer
2006 Ford F350 Lariat
112,428 miles
4x4
Sold! Thanks Brian in NY ❤️
$11,400
Need a reliable Powerstroke?
Find your Bulletproof 6.0