How Much Does It Cost To Bulletproof 6.0 (labor & parts)

Ford has tried their best to make the 6.0 Powerstroke durable. But no matter what, the engine may fail due to design defects or other elements like high heat, excess pressure, corrosion, and contamination. But the chance of damages can be avoided once you consider bulletproofing them. You may find it pretty expensive but it’s worth spending. 

The average cost to bulletproof Ford 6.0 engine can be $10,000 including labor fees. However, it can range from $3,000 to $20,000 or more depending on the number of components to be upgraded, type of design, how comprehensive you want it to be, labor charge of total hours, and other factors. 

Not only will the upgrade increase the power and lifespan of engine but also protect it from external damage. Since the price range is confusing, I’ve tried breaking down the cost here so it gets easier for you to understand. 

How Much Does It Cost To Bulletproof 6.0 (labor & parts)

How Much Does It Cost To Bulletproof 6.0? [Table]

Upgrade of any component of 6.0 will come with a charge. This table shows you the price range of 6.0 parts that may take to bulletproof. 

ComponentsCost Range
Oil cooler$2000-$4000
Exhaust Gas Recirculation$100-$400
Fuel tank$450-$5000
Fuel Injection Control Module$800-$4800
Water Pump$300-$400
Head Studs$600-$3800

Ford 6.0 Bulletproof Upgrades Cost Breakdown

It might take from a mere $100 to over $5000 to bulletproof components of 6.0. Here’s a detailed breakdown of the cost. 

#1- Bulletproof 6.0 Oil Cooler

Oil cooler is a radiator that maintains oil supply at a steady temperature. It removes excess heat and keeps the engine cool. 

Pros Of Bulletproofing 6.0 Oil Cooler

  • Reduce extreme temperature. 
  • Prevents the risk of premature injectors and EGR failure.
  • Improve oil cooling in the vehicle.
  • Allows the engine to warm up efficiently in colder weather. 

I’d recommend bulletproofing the 6.0 oil cooler if you take a look at the benefits. It might be quite expensive but worth going for. For the components, you may need to spend around $2000 to $4000. And installation charge can be from $700 to $1000. 

Since it’s connected with EGR, the failure of cooler due to internal damages can leave the EGR system starved. And this can result in severe damage to cooling material followed by restricting pressure and uplifted head. However, upgrading the part can reduce most issues. 

In case, you aren’t planning to own the truck for a longer period, you can skip the upgrade. Instead, I’d suggest you replace the oil cooler with OEM Ford parts. It’s pretty cheap and will take around $350. And the tech may charge around $800 to $900 for 10-hour labor service. Even if you sum up the cost, it’s still lesser than bulletproofing one. 

Note that, Ford oil cooler typically lasts 50,000 miles depending on maintenance, condition, and other factors. Contrariwise, bulletproofing can increase mileage by 60,000 to 100,000. So, you’ll have to bear several changes at the cost of one bulletproofing. 

#2- Bulletproof 6.0 Exhaust Gas Recirculation

EGR cooler mainly calms down the heat coming out of exhausted gas and lessens the Nitrogen Oxide emissions of the truck. It works with the oil cooler and ensures keeping the system cool. 

Pros Of Bulletproofing 6.0 EGR

  • Makes the 6.0 Powerstroke more durable. 
  • Eliminates the chances of emission problems.
  • Reasonable upgrade. 
  • Solid stainless steel construction to get rid of design defects. 

EGR can fail easily due to thermal stress. So, upgrading it is pretty important. One good thing is that it’s going to be inexpensive. You can bulletproof 6.0 EGR at around $400 including labor fees. 

However, you can also consider opting for 6.0 EGR delete kits that would cost under $100. Then again, it might violate Federal law, hence putting you at risk of fines and penalties. So, I don’t think you should go with it. 

#3- Bulletproof 6.0 Fuel Tank

The function of fuel tank is simple, i.e. to store and provide combustion chambers with fuel. 

Pros Of Bulletproofing 6.0 Fuel Tank

  • Prevents corrosion and contamination.
  • Avoids leaks. 
  • Welds won’t weaken.  
  • Vehicles warming up well.
  • Smooth flow of fuel. 

To upgrade fuel tank, the cost depends on different factors such as the panel design, material, and the number of panels.

Each panel may come with a price tag of around $450 to $1700. I’d prefer to go with a high-end one. Because it ensures better coverage and heavy-duty performance. 

A self-sealing tank is quite expensive. You may have to spend $2000 to $5000 for the upgrade. But they are a better option too since the internal layers of material prevent leaks and ignition if the external ones get damaged. 

The price can vary based on which method you pick. Professional installation will be costlier than DIY. 

#4- Bulletproof 6.0 Fuel Injection Control Module

FICM is the manager of injection pump. It controls the fuel efficiency and performance section of the Ford. 

Pros Of Bulletproofing 6.0 FICM

  • Includes a new Ford OE logic board.
  • Helps prevent the violation of engine trouble codes.
  • Stabilize over voltage but requires a timer for that.
  • No stuttering and starting issues.
  • Better supply of power and performance.
  • Noticeable increase in mileage. 

The upgrade of 6.0 components can cost around $1600 including labor fee. If you exclude the service, it’d be between $800 and $1000. To bulletproof Ford super duty trucks from 2003 to 2007, the price can increase from $4500 to $4800. 

However, you’d need to get a timer in case you upgrade FICM. This will help prevent over-voltage codes. 

Since it’s pretty expensive, you can consider other efficient ways. One of them would be to get a durable product. I suggest buying a TechSmart FICM power supply that comes with an OE cover. It costs around $150 to $230 and is quite reasonable.  

#5- Bulletproof 6.0 Water Pump

Water pump works to circulate coolant throughout the cylinder block, head, hoses, and radiator and prevents them from overheating. 

Pros Of Bulletproofing 6.0 Water Pump?

  • Prevents corrosion.
  • Better durability. 
  • Resists excess heat. 
  • Long-lasting belt.
  • Better sealing.

It may cost from $300 to $400 to bulletproof water pump, minus the labor cost. In case you have it done by a technician, then they may charge around half of the component cost. 

Since it’s quite expensive, I wouldn’t suggest going ahead with this upgrade unless it’s necessary. Instead, you can consider buying an Alliant water pump that’s just about $110. It comes in metal and feels like a bulletproof one. 

#6- Bulletproof 6.0 Head Studs

Head studs are the connecting components between the cylinder block, gasket, and cylinder head. 

Pros Of Bulletproofing 6.0 Head Studs

  • Enhances head-and-block gripping force of the vehicle. 
  • Better alignment. 

Not a very important upgrade unless you have enough money to spend on it. Bulletproofing Ford 6.0 head studs will give you the same benefits as replacing one. It wouldn’t bring significant change in the system. On top of that, it’s going to be quite steep coming at $600 to $3800. 

If I break it down, then it’s around $500 to $3300 for the parts and $400 to $500 for installation fees. As you can see, the service charge of installing is quite huge since it takes a lot of effort to upgrade them. 

I think you should pay more attention to the oil cooler and EGR cooler here. If you have them bulletproofed, there’s no chance of uplifted heads. Even if they do lift, then have them fixed or replaced by a tech which would cost less than the total cost of upgradation. 

Read also >> 5 Common IPR Valve/Sensor Failure Symptoms 6.0 Powerstroke

Does A 6.0 Need To Be Bulletproofed?

The requirement of bulletproofing 6.0 depends on whether the parts got damaged, which parts have failed, and severity of damage, and personal preference. 

It’s unnecessary to bulletproof if the engine is functioning well. Also, you don’t have to upgrade the entire system if a small part fails. Just check which of them has problems and then determine whether to develop it or not. You may also need to consider service charge too.

For instance, an oil cooler can bring a noticeable change if you get it bulletproofed. Meanwhile, head studs upgrade will cost a lot but there won’t be massive benefits in return. 

So, take a step only if it’s necessary and worth the expense. Once you get the common failure points and know how to improve them, then you can save yourself from spending more money. 

However, bulletproofing the necessary parts is beneficial. It does give you a variety of benefits apart from keeping the engine in good shape for a long time. 

Why Bulletproofing 6.0?

  • Bulletproof pickup trucks can last for around 400,000 to 530,000 miles thanks to improved protection and engine efficiency.
  • Addition of traction bars ensures reinforced trucks. 
  • Upgraded suspension offers safe driving conditions at a higher speed. 
  • Prevention of different failures.
  • Reduces the exceeding temperature. 
  • Produces more torque during ignition and acceleration.

How Long Does It Take To Bulletproof 6.0 Powerstroke?

It may take from 20 hours to 8 days to bulletproof 6.0 Powerstroke depending on whether it’s the entire system or certain parts. 

Gaskets, head studs, and EGR can take around 20 to 34 hours to bulletproof. Meanwhile, upgrading an entire OEM truck or raptor can take up to 7 or 8 days. 

If the technical support and effort are strong, the time can be reduced by 1 or 2 days. 

Frequently Asked Questions (FAQs)

1. How Long Does A Bulletproof 6.0 Last?

Bulletproof 6.0 can last up to 530,000 miles. 

However, you have to keep it well-maintained otherwise the mileage range will reduce. Plus, make sure to get it upgraded by a reliable tech since the procedure is complex and requires adept hands. 

2. Is The 6.0 Power Stroke Reliable?

6.0 Powerstroke is quite reliable since it can last up to 300,000 miles if maintained properly. 

You have to make sure to change oil and fuel filters regularly so it stays in good shape. Not just that, you must keep the system clean and ensure the lift pump supplies pressure properly. 

However, the engine may still fail due to different causes such as extreme pressure and heat. You can reduce the risk by bulletproofing it. 

3. Can I Bulletproof My 6.0 Myself?

You can bulletproof 6.0 yourself as long as you have the required skill and proper knowledge of technical methods

In case you’re a beginner or have to study the procedure, then I’d suggest leaving it to the expert. 

How much was”BULLETPROOFING” MY 6.0? (Was it worth the money? waste or worth >> check out the video below:

Final Words

Before you take step to bulletproofing, check the engine components and the malfunctioning condition. Typically, 4 out of 6 pattern failures need to be addressed to bulletproof. The parts include an oil cooler, EGR cooler, FICM, water pump, fuel tank, and head studs. 

However, it still depends on how serious the problem is. And if the entire system is failing, then you must bulletproof 6.0L Ford Powerstroke Engine

Who Worked on This post?



Anderson is an experienced auto mechanic with over 10 years in the industry. He is skilled in diagnosing and repairing a wide range of vehicles, from sedans to trucks and SUV

Syed Ahmed


Syed Ahmed has been working as an auto mechanic editor for the past five years. He has a background in mechanical engineering and a love for all things automotive

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