Cost of Bulletproofing a 6.4 Powerstroke Engine (labor & parts)

Though the Ford 6.4 Powerstroke was a great improvement from its predecessor, 6.0L, all problems were not gone. As a result, to enhance the longevity, safety, and performance of the Ford 6.4 diesel engine, bulletproofing is also an effective solution for 6.4L, like 6.0L. how much does it cost to bulletproof a 6.4 Powerstroke. Okay, here we have to be a little diplomatic.

The cost of bulletproofing varies from factor to factor, like parts cost and labor cost. You can assume an estimated cost of $3000 to $8000 or more to bulletproof your 6.4 Powerstroke entirely.

As the cost differs regarding various factors, a precise explanation of the differentiation of cost factors is needed. In this article, we will discuss the cost of different parts to bulletproof a 6.4 as well as the labor cost. Alongside them, we will give some relevant suggestions too.

How Much Does It Cost To Bulletproof A 6.4 Powerstroke

What Does Bulletproof Mean For A Diesel Engine?

To get to the point, the meaning of “Bulletproofing” must be clarified first. Bulletproof means to us something indestructible. But the term is entirely different for diesel engines.

“Bulletproofing” for the car is a particular term inducted by Bulletproof Diesel means upgrading the car’s diesel engine to protect and enhance its performance, longevity, and safety. The terms are specially made for Ford 6.0L Powerstroke.

By the way, the term got famous when the diesel engine parts manufacturer Bulletproof Diesel was founded in 2009 in Mesa, Arizona.

Bulletproofing focuses on Ford’s 6.0L, 6.4L, and 6.7L Powerstroke engines, and Bulletproof Diesel started the trend by providing almost all the necessary parts for diesel engines to bulletproof them.

How Much Does It Cost To Bulletproof A 6.4 Powerstroke?

The cost to bulletproof your 6.4 Powerstroke mainly depends on two factors. The parts and the labor cost.

#1- Parts cost

Simply put, a lot of parts, from smaller to bigger, ought to be upgraded regarding bulletproofing your 6.4 Powerstroke. Mainly, 6 areas of a 6.4l are considered to be upgraded for being bulletproof. They are-

  1. EGR Cooler
  2. Oil Cooler
  3. Water Pump
  4. Head Gasket with Head Stud
  5. FICM- Fuel Injector Control Module
  6. EGR Delete*

Note:* EGR delete is sometimes considered to be implemented by many. But most professionals don’t suggest EGR deletion; rather, upgrading the EGR cooler.

Here is a list following the purchasing price of the above-mentioned products to get an idea about their cost.

ProductsApproximate Cost
EGR Cooler complete kit (Cooler vertical, cooler horizontal, and gasket set)Around $1000 ($450+$520+$20)
Oil Cooler setAround $1600 to $2300
Water Pump$500 to $600
Head Gasket with Head studs (installation kit if needed$700 to $1700
Fuel Injector Control Module (FICM)Around $1200
EGR delete (not recommended though)Around $100

Now let’s have some explanation on the products mentioned-above to bulletproof your Ford 6.4 Powerstroke.

#1- EGR Cooler Kit Cost

An entire and efficient set of  EGR cooler kits with TIG welding will cost you around $1000.

EGR refers to Exhaust Gas Recirculation. The EGR valve helps to recirculate the exhaust gas to the engine to reduce NOx emission. This ensures fuel efficiency, acceleration, and power of your 6.4 Powerstroke.

The failure of the EGR cooler system does vice versa.

#2- Oil Cooler Cost

The oil cooler removes your engine’s surplus heat to keep the engine cool. It also keeps the transmission system cool as well. When it fails or decreases in performance, your engine will get more heat and less performance.

Besides, the oil cooler is a small radiator. It keeps the engine cool while running by giving fresh air to the engine oil through the water-based radiator.

The entire oil cooling set will cost around $1600 to $2300.

#3- Head Gasket Set

The head gasket set will cost you around $700 or more. On the other hand, the set with the installation kit will cost more, around $1700. We don’t recommend purchasing the installation kit if you are not an auto repair professional.

As the head gasket seals and prevents your coolant and engine oil from leaking into the cylinders, it’s worth replacing. Actually, the head gasket is not a problem. Issues happen when the cooling system and EGR system fails or drops.

But when it happens, a faulty head gasket may cost thousands of bucks to repair the engine afterward. By the way, head studs are recommended instead of head bolts for efficient patchings and sealing.

#4- Water Pump Cost

With a high-grade aluminum impeller instead of a plastic OEM impeller, a water pump can cost you around $500. The aluminum impeller is much sturdier than plastic, lessening the chance of cracking.

Likewise, the water pump pushes the coolant to the engine through the coolant system. Your engine cooling system is nothing without the water pump. So, it’s worth replacing the water pump to upgrade your 6.4 to bulletproof.

#5- Fuel Injector Control Module (FICM) Cost

A good aluminum housing, great heat dissipation, and an updated fuel injector control module (FICM) costs around $1200.

However, the FICM must be in pristine condition and fully functioning. The electrical supply is powered by the FICM to the fuel injector. The power supply generates the power to the logic board, and the logic board controls the fuel injector.

Therefore, the FICM is crucial to the function of the fuel injector to flow the right amount of fuel to the engine.

#6- EGR Delete

As we mentioned before, EGR recirculates the exhaust gas in the engine’s intake system. As a result, the gas is re-flown to the engine and lessens the emissions.

But sometimes, the EGR may develop a clogged intake system. As a result, some 6.4l users might want to replace the EGR with an EGR delete kit. It means the EGR delete will remove the EGR valve and stop the gas recirculation. The EGR kit may cost you around $100 to purchase.

By the way, experts suggest not replacing the EGR cooler with EGR delete kits. It will cause your car to fail emission tests. Because of this, EGR deletion is illegal in 50 states.

Aside from these, some parts could be upgraded when they fail. They include

  • Exhaust systems
  • Fuel systems
  • Air intake systems
  • Emission equipment
  • Turbocharger
  • Fuel injectors, etc.

Labor cost and the determination criteria

All we have discussed is the purchasing cost of the products. And only purchasing is not the end of your cost when it comes to making your 6.4 Powerstroke bulletproof.

The labor cost remains yet. Actually, the labor cost is a big portion of your 6.4l bulletproofing process. This cost is not fixed. Several factors impact the determination of labor costs.

They include-

  • The area of the repair shop. The urban or downtown area costs a lot compared to the rural area
  • If the shop is authorized, the cost will be more. On the other hand, independent shops will cost less, expectedly
  • Also, the car model is another big factor that impacts the labor cost

With all criteria mentioned above, the labor cost in the USA varies from $75 to $150 per hour. So, the total labor cost will be calculated after completing the entire process in which area you have done this, and how many hours the mechanic worked.

How to Bulletproof 6.4 Powerstroke? (video guide)

To put it simply, bulletproofing is extensively a professional task. So, we will suggest you take professional treatment for bulletproofing your 6.4 Powerstroke.

You may check out the following video bulletproofing a 6.4 of For F450.

frequently asked questions (FAQs)

Now look at these common questions people asked about bulletproofing a 6.4 Powerstroke. It will give you more insight.

Is Bulletproofing Really Worth It?

Yes, bulletproofing is worth it when you want your 6.4L to last a long time with strength, and performance. Basically, the 6.4L Powerstroke lasts around 150000 to 200000 miles. Bulletproofing will enhance efficiency, performance, and strength for a much longer time.

key summary

How much does it cost to bulletproof a 6.4 Powerstroke finally? Since it depends on several factors, the cost is not static. You have to spend on products as well as labor.

Also, you might not change everything. In this case, the cost will be less. But in summation, a minimum estimated cost of around $8000 is expected if you want to replace everything assessed to make your 6.4 Powerstroke bulletproof.

Want more powerstroke articles like this? Here are other related articles you might like:

7.3 Powerstroke Rebuild Cost Backdown – [Parts & Labor Cost]

How Much Does It Cost To Bulletproof 6.0 (Labor & Parts)

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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