Ford F-Series: How to Install 6.0 Bulletproof Kit
Want to make your 6.0 Power Stroke last forever? Here's a detailed list that'll make it a bulletproof engine instead of a potential liability.
This article applies to the Ford Super Duty, Econoline, and Excursion (2003-2010).
Ford's 7.3-liter Power Stroke is one of the most beloved diesels of all time. Sadly, stricter emissions standards forced them to switch to a 6.0-liter late in the 2003 model year of the Super Duty, where it remained until 2007. The diesel was also used in Econoline vans and the Excursion SUV. Unfortunately, there are a number of well-known issues with the 6.0 models. Fortunately, however, there are plenty of ways to overcome those weaknesses and essentially "bulletproof" your oil burner. Here's how to get started.
Key Information
- DIY Time: 8-10 hours
- DIY Cost: $1,200-$8,000
- Professional Cost: $2,000-$10,000
- Req. Skill Level: Moderate to Difficult: requires some mechanical skill and specialized tools.
Materials Needed
- Bulletproof kit
- Assorted sockets and wrenches
- Jack and jack stands or lift
- Torque wrench
- Coolant
- Engine oil
Step 1 - Choose a Bulletproof Kit
If you do a simple internet search for "6.0 Bulletproof," you'll return thousands of results. There are many, many companies out there selling many, many different kinds of solutions. The biggest difference between all of these kits is the number and types of components they include. Top of the line kits like this one sold by Bulletproof Diesel will come with air-cooled oil coolers, heavy duty oil filtration systems, head gaskets, and all the hoses and fittings you need to get the job done. Here we'll break down your various options and what you can expect from them.
Step 2 - Basic Bulletproofing
If your truck is running well at the moment but you're looking to add some protection against future head gasket problems, less work is necessary. The first thing you'll want to do is replace your oil cooler with an OEM unit or a reputable aftermarket cooler. When it comes to the EGR cooler, you've got two choices - either replace it or delete it entirely, which will depend on your state's emissions laws.
Next, you'll want to flush all your old coolant, replace it, and get a new coolant filter. Once this is finished, a custom tune will adjust your fuel delivery and help protect your head gaskets while also improving performance. Finally, you'll want to replace your coolant cap and thermostat, which are cheap and easy ways to add extra insurance.
Step 3 - Longer-Term Bulletproofing
If you already have head gasket problems with your 6.0, you'll need to do a little more work to set things right, in addition to those steps outlined in Step 2. The first step, of course, is to replace your factory head gaskets with heavy duty ones, along with beefy head studs (such as those made by ARP) to hold it all together. Additionally, it isn't a bad idea to take your heads to a machine shop and have them checked out.
Additional steps that can help include cleaning up your turbo and fuel system, checking your A/C system, replacing the water pump, and fitting new O-rings to make the new head gaskets stable. At this point, it's also a good idea to change the oil and even your fuel filter to ensure optimal performance.
Step 4 - Lifetime Bulletproofing
If you plan on keeping your 6.0-powered truck forever and don't want to worry about the head gaskets ever again, there are some additional steps you can take. A proprietary head gasket coating, remanufactured cylinder heads, a coolant bypass system, and a tuner that monitors the engine constantly are all great investments in this case. These steps require significantly more investment and time, obviously. But in the end, you'll have a diesel that'll last a lifetime!
Related Discussions
- Best 6.0 Bulletproof Kit?- Ford-Trucks.com
- Total Cost to Bulletproof a 6.0? - Ford-Trucks.com
- How to Correctly Identify a Bulletproof 6.0 - Ford-Trucks.com
