6.0 PowerStroke Bulletproofing Guide - Boosted Performance

The Ford 6.0 PowerStroke engine is known to have a few reliability issues. Problems with the emissions, oiling, and fueling systems are all common and potentially expensive repairs. As such, it's common to upgrade these components to improve reliability and the term "bulletproofing" quickly caught on.

An oil cooler, EGR cooler, head gasket & studs, FICM, and water pump are among the best 6.0 PowerStroke bulletproof upgrades. In this guide, we discuss these mods in-depth to help improve the reliability of your 6.0L diesel engine.

6.0 PowerStroke Bulletproofing Upgrades

• Oil cooler
• EGR cooler
• Head gasket & studs
• Fuel injector control module (FICM)
• Water pump

The above list encompasses the most common failures on the 6.0L PowerStroke. They are the generally accepted reliability upgrades known as bulletproofing the engine. However, upgrading all 5 areas is an expensive project so it may not be worthwhile for everyone.

In our experience, the 6.0 PowerStroke bulletproof upgrades are best suited to those looking to own and modify the truck for the long-term. That said, it's still a good idea to address at least a couple of these problematic areas.

1) Oil Cooler Mods

This list isn't in any particular order, but oil cooler upgrades are first for a reason. Oil cooler failure can potentially cause an array of issues:

1. Oil cooler coolant passages become blocked
2. Starves EGR cooler and causes it to overheat and fail
3. EGR cooler failure may lead to coolant in the intake
4. This causes high-pressures that are known to lift the head

Issues with the EGR cooler and head lifting are next up on this list of bulletproof upgrades. They're already problematic areas that can be further exacerbated by an oil cooler failure. As such, the oil cooler is one of the most important bulletproof upgrades.

However, oil cooler upgrades can be very expensive depending on the route you go. Bullet Proof Diesel sells their oil cooler upgrade kits for $2,000+, for example. Fortunately, there are other effective and much more affordable options.

Pacific Performance Engineering Oil Cooler Kit

We offer the PPE Heavy-Duty replacement oil cooler kit for just $249.99. This oil cooler promotes more effective engine oil cooling and reduces oil temperatures feeding the EGR, injectors, and HPOP. It's designed with stronger internal passageways and also adds an additional row of oil passages.

Ultimately, the Pacific Performance Engineering oil cooler kit is a great upgrade for peace of mind at an excellent price. Those looking to keep their 6.0 PowerStroke for the long-term may find more value in full-blown upgrades like the Bullet Proof Diesel kit. However, solutions like the PPE kit are much more budget-friendly and help achieve the end goal of making the 6.0L diesel more reliable.

2) EGR Cooler Upgrades

Next on the list are 6.0 PowerStroke EGR Cooler upgrades. One option is an EGR delete kit. However, deleting the EGR is illegal and should not be done on street-legal trucks. Instead, an EGR cooler upgrade is a great way to keep your truck legal while solving one of the main reliability issues.

Fortunately, these upgrades are also relatively inexpensive. Most 6.0 PowerStroke EGR cooler upgrades fall around the $400-500 range. We offer BD Diesel EGR coolers with a 5-year warranty (though, they tend to last the lifetime of the engine). The BD EGR cooler uses TIG welded 304L stainless steel and has water deflectors to increase turbulence and aid in heat dissipation.

3) Head Gasket & Head Studs

There are two different reasons the 6.0 PowerStroke experiences head lift. It isn't a design flaw with the head, gaskets, or head bolts. However, as discussed earlier, oil cooler and EGR cooler failures occasionally lead to head problems. The second cause of failure is due to modding and tuning.

Addressing the head gasket and studs is more important for those looking to upgrade their 6.0 PowerStroke for bigger power builds. When it comes to studs, ARP head studs are the most popular option for good reason. It's an excellent head stud kit at a good price. We offer the 6.0 PowerStroke ARP head stud kit (including the M8 inner row head bolts) for $599.

As for the gaskets, the OEM head gaskets are actually one of the best options. The gaskets really don't have a design flaw and failure often occurs simply due to natural age, wear & tear, or issues with the head lifting. The main reason to to a full head gasket kit is for added reliability while doing head studs. We offer the OEM Mahle Black Diamond complete gasket kit.

4) Fuel Injection Control Module (FICM)

As the name suggests, the 6.0 PowerStroke FICM controls the fuel injectors. Issues with the FICM will cause trouble starting or no start. Rough idle, stuttering, and power loss are a few other common symptoms of fuel injector control module failure.

Fortunately, issues with the FICM aren't urgent in the sense they won't lead to any other reliability or longevity troubles. 6.0 PowerStroke FICM failure may leave you stranded, though. This is one of those bulletproof mods that we recommend waiting to address until you actually run into the failure.

A full fuel injector control module upgrade runs in the ballpark of $700-1,000+. Hence the reason we recommend holding off on this upgrade until the time comes. We offer the BD Diesel 58-volt FICM for $700 with a $250 refundable core charge.

5) Water Pump Bulletproofing

Last but not least, the water pump is another common issue on the Ford 6.0 PowerStroke. The OEM pump users a plastic impeller that's prone to cracking and breaking. Puddles of coolant under your truck are usually a sign your water pump failed. If coolant flow is lost or dramatically reduced then you'll also likely notice the engine overheating rapidly.

Currently, Boosted Performance does not offer any water pump upgrades for the 6.0L diesel (it's something we'll hopefully add to our catalog in the near future). The Bullet Proof Diesel water pump is a great option, though. It uses an aluminum impeller and features upgrades to the bearing assembly, seal, and housing.

At $400 it's a very reasonable price for a reliable water pump. There's no right or wrong answer as to whether you should do this preventatively. Either wait and upgrade when your OEM water pump fails or knock it out up-front to ensure the water pump won't leave you stranded.

Extra 6.0 PowerStroke Bulletproof Upgrades

The above 5 items are by no means an exhaustive list of all the issues that can or do arise on the 6.0L PowerStroke. They're generally the most common problems and a good starting point for building a reliable, bulletproof engine. However, a few other things to consider include:

• Coolant filtration kit
• Fuel injectors
• Oil pumps (HPOP & LPOP)
• Complete cooling system (beyond water pump, EGR, & filtration kits)

In most of these cases, it's best to wait until an actual failure occurs before opting for any of these extra upgrades. A coolant filtration kit is likely the one main exception. Ultimately, the 6.0 PowerStroke is an older engine and there are proven & effective long-term solutions to problems.

If you have a large budget and are planning to modify and keep your 6.0L diesel for years to come then it may make more sense to upgrade things preventatively when you're in the area. Otherwise, there isn't any reason to break the bank trying to address too many potential issues up-front.

Ford 6.0 Diesel Bulletproofing Summary

The 6.0 PowerStroke is a great engine overall but it's never had a great reputation for reliability. Some of the main issues include the oil cooler, EGR cooler, head & gaskets, water pump, and FICM. These are common areas to upgrade which is referred to as "bulletproofing the 6.0 PowerStroke".

Oil cooler and EGR cooler upgrades are two that we highly recommend as problems with these components can cause additional failures. The FICM and water pump are good to upgrade when problems actually arise. Finally, head gasket kits and head studs are mostly for those looking to further modify the 6.0 diesel for power and torque.

It's not an exhaustive list of all the potential issues and "bulletproof" upgrades. There are tons of reliability upgrades for the 6.0 PowerStroke but it's best to save these for when problems actually arise.

Have any questions about 6.0 PowerStroke upgrades or bulletproof mods? Please feel free to reach out as we're happy to help with any questions or advice!