6.0 Power Stroke Oil Cooler Upgrade

The Simple Solution From Bullet Proof Diesel

The 6.0L Power Stroke has gotten a bad rap over the years, thanks mostly to well-documented oil cooler and EGR cooler failures. Consequently, you can buy a used 6.0L Power Stroke relatively cheaply and the money you save on the purchase price can go towards addressing some of the engine’s shortcomings and building it to suit your uses and needs.

As a refresher, the 6.0L Power Stroke was introduced in 2003 after market pressure from Dodge and GM forced Ford to up their diesel power offerings. While the current 7.3L Power Stroke was reliable, Ford needed to counter the common-rail offerings from GM and Dodge and the 6.0L was the answer. Produced by the same folks who built the 7.3L Navistar, legend has it that Ford rushed Navistar to get the 6.0L to market quickly, and once on the road, design flaws started to show up.

Topping the list was failure of the factory EGR cooler. The folks at Bullet Proof Diesel, which is a division of Neal Technologies in Mesa, Arizona, say the EGR cooler failures were symptomatic of a much larger problem and replacing the cooler with another factory one only prolonged the agony and owner frustration. According to Bullet Proof Diesel, the real culprit behind these repetitive EGR cooler failures is not only the design of the stock EGR cooler, but also the truck’s oil cooler.

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Located at the front of the block, just under the intake manifold, the water to oil intercooler sits in an oil-filled recess in the valley of the motor, and supposedly is used to cool the truck’s hot oil by circulating coolant through the cooler. Unfortunately, the sandwich-style design of the cooler features tiny water passages which eventually get clogged with debris from the cooling system. These pathways are so small they catch and stop any large particles suspended in the coolant, blocking the coolant channel and consequently the coolant flow.

“The folks at Bullet Proof Diesel say the EGR cooler failures were symptomatic of a much larger problem and replacing the cooler with another factory one only prolonged the agony and owner frustration.”

A plugged engine oil cooler typically leads to a ruptured EGR cooler, overheated engine oil, overheated fuel injectors, loss of coolant, ruptured engine oil cooler and blown head gaskets, they add. Replacing the Ford engine oil cooler with another Ford engine oil cooler is the usual fix, but all that does is put off the problem for another 50,000 miles.

The new Bullet Proof Engine Oil Cooler/Factory Oil Filter kit comes complete with a billet engine oil block, high-pressure oil lines, external oil cooler and all the gaskets and fasteners you’ll need. Pictured here is the optional cold weather kit, which has a thermostatic-controlled flow for faster engine warm-up

This is the problem child… the factory 6.0L oil cooler. It sits in an oil-filled recess in the valley of the motor, and supposedly is used to cool the truck’s hot oil by circulating coolant through the cooler, assuming the coolant passages aren’t plugged.

This cut-away of the cooler shows the tiny oil and water passages inside. Debris in the cooling system is what causes the coolant side of the oil cooler to plug up, which can cause major issues downstream, including killing the EGR cooler.

The install starts by removing all the stuff on top of the motor including the turbo and intake manifold.

Fast forward: this is what things should look like when you’re done.

So what’s the long-term fix? Over the years, Bullet Proof Diesel has developed an external oil cooler system that utilizes a large spin-on oil filter that replaces the stock setup. They have also developed “bullet proof” EGR coolers with better construction for improved coolant flow.

Their latest offering is an all-new oil cooler system that retains the factory oil filter setup on top of the engine, while still incorporating a billet aluminum engine oil block that replaces the factory oil cooler which sends oil via high-pressure lines to a front-mounted oil cooler which sits behind the A/C condenser.

The most obvious benefit is replacement of the factory oil cooler, which can rupture and dump coolant in the engine oil. More importantly, the system provides cooler oil to the engine, injectors and high-pressure oil pump, which increases their longevity and performance as well. And for those folks in colder climates, where cold weather warm-up is an issue, the Bullet Proof kit can also be ordered with an in-line thermostat for quicker engine warm-up.

Installation of the kit is labor intensive since the whole top of the engine needs to be removed to access the factory oil cooler. The good news is this is a great time to also replace the factory EGR cooler with an upgraded Bullet Proof unit.

The system is a true bolt-on setup and comes with thorough instructions. There are some quirks associated with assembling and disassembling the top end of a 6.0L that might be best left to the professionals, but any good diesel mechanic should be able to install the system in less than two days, following the instructions to the letter.
If you own a 6.0L Power Stroke, it’s only a matter of time before the factory oil cooler, and EGR cooler, gives up the ghost. Why not get ahead of the game with simple upgrades from Bullet Proof Diesel? DW

This plastic filter sits in the oil reservoir under the factory oil cooler and is supposed to filter the oil headed to the HPOP. This is another failure area on the 6.0L and will be discarded for the install.

This is what the factory oil filter assembly looks like outside of the engine, complete with cap and dirty filter. This setup will be mounted to the new Bullet Proof oil transfer block assembly.

8a-b The new Bullet Proof oil transfer block assembly comes preassembled, complete with a new HPOP screen that’s aircraft wired on the bottom. All you have to do is install the new gasket. Another new gasket goes under the factory oil filter base.

With the gaskets in place, the factory oil filter assembly can now be bolted to the Bullet Proof Diesel manifold block.

The new assembly sits on top of where the old oil cooler was located.

Once bolted in place, you can reattach the original sensors and coolant line fitting which runs to the EGR.

Now, attention is focused at the front of the truck. Removing the bumper and grille assembly is mandatory to access the trans cooler and A/C condenser. Both are removed from the truck.

Some 6.0L Super Dutys came with a larger heavy-duty trans cooler. The kit includes new brackets to space it downward to make room for the new oil cooler. Some grinding of rivets is needed to take off the old brackets and bolt on the new ones.

This is what the trans cooler looks like with the new lowering brackets attached.

As per the instructions, the Bullet Proof Diesel oil cooler mounting bracket is attached to the top of the air conditioning condenser.

Install all the fittings next. Follow the instructions carefully to put the right ones in the right locations.

The cooler simply bolts into the mounting bracket using the supplied hardware and aluminum spacers to provide an air gap between the condenser and cooler.

Here’s what the finished assembly looks like. Not the solid transfer line’s location.

19-20 Believe it or not, the assembly simply slips in place and looks like a factory install. Better still, the oil cooler is behind the A/C condenser so A/C performance is not affected.

For this truck, Bullet Proof is installing the optional cold weather kit, which utilizes a thermostat block to assist in faster engine warm-up in cold weather. The instructions are very specific on which line goes where.

Before buttoning up the engine, the silicone coolant hose and clamp need to be installed on the block and EGR.

New intake manifold gaskets are included in the kit for re-installation.

With the intake manifold installed, next up is the oil and fuel filter assembly.

The turbo pedestal goes on next as does a new turbo drain line since there’s a factory upgrade now available.

The turbo is ready to install. It’s heavy and awkward to install at the back of the motor. Once in place, time to connect all the plumbing including oil lines and up-pipes.

Finishing touches include a fresh factor oil filter. Make sure your truck has the correct oil filter cap to work with the factory filter.

Running the lines and attaching the thermostat block is all that’s left to do under the hood.

The finished install is very stealthy, with the exception of the visible cooler lines.

SOURCE:
Bullet Proof Diesel
888-967-6653
www.bulletproofdiesel.com

FREQUENTLY ASKED QUESTIONS

How does the external oil cooler kit perform in extreme temperatures, such as those in Alaska or Nevada?

Performance of the External Oil Cooler Kit in Extreme Temperatures

Are you wondering how an external oil cooler kit manages in extreme climates like Alaska or Nevada? Let’s dive into it.

When faced with the frigid temperatures of Alaska, where the mercury can plunge to -30°F, this system proves its worth. It aids in quicker engine warm-ups, maintaining a minimal temperature difference—just 3°F—between oil and coolant. This ensures the engine runs smoothly regardless of the cold.

On the flip side, Nevada’s sweltering heat, often surpassing 100°F, presents an opposite challenge. Yet, the cooler kit excels by keeping oil temperatures in check, never exceeding 210°F. Even when towing a hefty 12,000-pound trailer up steep grades and summits, the engine remains unfazed.

In both extreme conditions, from icy colds to scorching heat, the external oil cooler kit delivers consistent performance, ensuring the vehicle’s reliability no matter what the thermometer reads.

What issues might arise from not including installation instructions with an external oil cooler kit?

The Pitfalls of Excluding Installation Instructions with an External Oil Cooler Kit

When purchasing an external oil cooler kit, installation instructions are crucial for a seamless setup and optimal performance. Here are key issues you might encounter without adequate guidance:

Confusion During Installation: Without clear instructions, you’re left to navigate a potentially complex installation process, leading to significant confusion. Unlike straightforward plug-and-play setups, oil cooler installations can demand intricate knowledge of vehicle-specific details, such as hose routing and component placement.
Risk of Incorrect Assembly: Lacking guidance increases the chances of assembling components incorrectly. For instance, the direction in which hoses should be installed might vary depending on specific vehicle modifications, such as a “gen3 ear delete.” Installing parts in the wrong configuration could hinder performance or even damage the vehicle.
Potential for Missing Components: An absence of instructions means you might not immediately realize if crucial parts are missing. Without a checklist, it’s easy to proceed with an incomplete kit, only to discover a missing component halfway through the installation.
Variation in Equipment Specifications: Kits often include parts that must be used precisely for them to function properly, like a “36-inch” versus “34-inch” hose. Instructions generally guide this specification process, but when they’re absent, it can lead to misuse or inefficient performance.
Time-Consuming Installation: Instruction-less installations usually require more time, as they’re fraught with trial and error. This process can be frustrating, turning a straightforward job into an all-day project unnecessarily fraught with challenges.
Reliance on Third-Party Sources: Without official instructions, you might need to seek guidance from external sources like YouTube tutorials or automotive forums. While helpful, these can vary greatly in accuracy and relevance to your specific kit and vehicle setup.
Doubts About Product and Company Credibility: A lack of instructions might lead to questioning the credibility of the manufacturer. It suggests a possible oversight in quality control and customer support, potentially affecting your trust in the product and the brand overall.

In summary, not providing installation instructions for an external oil cooler kit can lead to confusion, mis installation, time waste, and even potential damage. Clear, detailed guidance is essential to ensure the product is used effectively and safely.

What are some of the bestsellers in the category of Ford 6.0 Powerstroke parts?

Top Ford 6.0 Powerstroke Parts

If you’re on the hunt for some of the most sought-after components in the Ford 6.0 Powerstroke parts category, look no further. Here’s a curated list of top performers that enthusiasts and mechanics alike swear by:

High-Flow Coolant Filters
Ensure your engine runs smoothly by minimizing debris with a high-quality coolant filter designed specifically for Ford 6.0 systems.
Turbo Oil Drain Tubes
Upgrading your turbo oil drain tube can enhance your engine’s efficiency and reduce the risk of leaks, making it a must-have modification.
Valve Train Retainer Rocker Arm Clips
These clips are essential for maintaining the integrity of your engine’s valve train, providing peace of mind and reliability.
Diesel Fuel Injector O-ring Rebuild Kits
Tackle common injector seal issues with a comprehensive rebuild kit, ensuring your engine maintains optimal performance.
Intake Gasket Kits
A proper intake gasket kit is crucial for preventing air leaks and maintaining fuel efficiency in your Powerstroke engine.
Oil Cooler Gasket Kits (2003-2007 Models)
Ensure proper oil circulation and prevent leaks with a reliable gasket kit tailored for early 2000s models.
EGR Exhaust Block Off Plates
Many owners choose these plates to test their EGR systems, which can help with performance diagnostics and maintaining vehicle efficiency.
Genuine Oil Cooler Kits
For those seeking peace of mind, OEM oil cooler kits are ideal for ensuring components fit seamlessly and perform as expected.

These components have been carefully chosen to meet the needs of Ford 6.0 Powerstroke enthusiasts, whether you’re performing routine maintenance or seeking to enhance performance.

What are the suggested additional components for a flawless installation of the external oil cooler kit?

The new Bullet Proof Engine Oil Cooler/Factory Oil Filter kit comes complete with a billet engine oil block, high-pressure oil lines, external oil cooler, and all the gaskets and fasteners you’ll need. Pictured here is the optional cold weather kit, which has a thermostatic-controlled flow for faster engine warm-up.

To ensure a flawless installation and optimal performance, consider adding these recommended components:

Filter Option: This ensures that 100% of the coolant passing through the cooler is effectively filtered, maintaining system efficiency.
Stainless Steel Sump Screen Option: This addition aids in keeping the system clean and prevents debris from causing blockages.

The system is designed with large 3/4″ hoses, ensuring ample coolant and oil flow through the cooler. With these enhancements, you can expect a seamless installation and long-lasting performance. Plus, maintenance is simplified—cleaning the stainless steel filter is a breeze, making it unlikely that you’ll need to replace the oil cooler again. If you ever do, the process is straightforward and can be completed in about 45 minutes.

What additional components are recommended for optimal installation and performance?

It is recommended to purchase both the filter and the stainless steel sump screen options to achieve the best installation results.

What are the benefits of the system’s design?

The design allows for easy access to the oil cooler, making replacement quick if needed, and it includes large hoses to ensure ample flow of coolant and oil.

Is there any maintenance or cleaning required for the system?

Yes, regular cleaning of the stainless steel filter is necessary to ensure optimal performance.

What should be done when the deltas start to rise?

Simply clean the stainless steel filter to maintain the system’s efficiency as deltas begin to increase.