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Ford 6.0L Power Stroke Problem Solvers

Bulletproof EGR And Oil Cooler Upgrades For '03 To '07 Fords

Text By Jason Thompson, Photography by

Engine oil and coolant are the interrelated lifeblood of the 6.0L Power Stroke. If a clot should form, preventing flow, or the fluids become mixed, severe damage can be done to the injectors, high-pressure oil pump (HPOP), engine bearings, heads, turbo, block, and pistons. The symptoms to watch out for include: steam coming out of the exhaust pipe, the puking or unexplained loss of coolant from the overflow bottle, and coolant or sludge in the intake manifold when you remove the EGR valve. A thick, black ooze in either the engine coolant or oil systems and internal sections of the intake manifold that look like they've been steam-cleaned is also a sign that something is wrong. The factory liquid-to-liquid engine oil cooler (EOC) situated on top of the 6.0L directly below the oil filter is prone to clogging because the internal coolant passages are narrow and BulletProofDiesel (BPD) says the 6.0L requires 181/2 gallons of cooled oil per minute at peak demand. BulletProofDiesel's solution is to replace the factory oil cooler and filter with a remotely mounted air-to-liquid cooler and spin-on filter. The other line of defense is an upgraded EGR cooler. This operation turned an '03 Ford into a reliable diesel truck that still has functioning emissions equipment. This isn't the first time we've operated on one of these potentially reliable engines; for more critical information see "Every 6.0L Problem Solved," in the July '09 issue of Diesel Power magazine.

PRICE LIST:
BulletProofDiesel oil cooler upgrade (6.0L condenser mount) $1,895
BulletProofDiesel EGR cooler upgrade (round) $450
SOURCES
Bulletproof Diesel
134 East Broadway Road
Mesa
AZ  85210
888-967-6653
http://www.bulletproofdiesel.com
/
By Jason Thompson
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138 comments
Mike LeVeck
Mike LeVeck

6.0 is a great engine, when taken care of,however, i would rather have everyone believe it's a POS so i can get the deals.

Kevin E Gracie
Kevin E Gracie

I'm looking at and 07 F-350 with the 6.0 in it, is there a way to tell if the EGR/ oil cooler has been updated in it. Also if I get it I wanted to put turbo back exhaust, intake and a programmer on it not looking to make big power just a little extra. Will this cause any extra problems.

Pit Castillo
Pit Castillo

if you are smart you can study all the motor functions and understand how work, but you need equipment, and if you have equipment you need be smart too... when you have all then 6.0 is a GOOD MOTOR.

Pit Castillo
Pit Castillo

6.0 is a real good motor,, but on stupid mechanics is the worst

Fabián Ortiz Nazario Brunno
Fabián Ortiz Nazario Brunno

It is funny that after the BILLIONS $$$$ NAVISTAR spent on its ANTI-SCR campaing and advocated that their ADVANCED EGR and MAXXFORCE engines would be the hassle free solution their ADVANCED EGR fiasco went down with full force. Ohhh they turn to CUMMINS for help after they trashed SCR emission treatment systems... Wasn't DEF toxic acording to Navistar???? Kharma is a ***** !!!

Christian Lynch
Christian Lynch

Think idi can't make big horsepower?Back in the early 1990s, max Lagod of Hypermax put together an extraordinary engine package for a customer yearning to compete in sled pulling. With nothing holding him back, Lagod designed a 7.3L that included two Garrett turbos (which were state-of-the-art then but probably not manufactured anymore), a Bosch inline P-pump, custom injectors, a fabricated intake and exhaust manifolds, and slight cylinder head work. Surprisingly, much of the factory engine components were retained, such as the crankshaft, block, and pistons-although the connecting rods were heat-treated. Compression on the engine was 15:1, which called for ether-assisted startups. Soon after entering this wild IDI into area-sanctioned sled pulling events, the engine was banned. Not to be discouraged, the owner turned to drag racing. Rumor has it that the truck graced with this 7.3L beast put out 1,200 hp and ran quarter-mile times in the 9-second range! Read more: http://www.dieselpowermag.com/tech/ford/0810dp_ford_diesel_truck/viewall.html#ixzz2hjpidJnX

Christian Lynch
Christian Lynch

The 7.3L Power Stroke is based on International's T444E (the name "Power Stroke" is unique to Ford vehicles). The T444E has been offered in applications exceeding a 60,000 lb GVWR; the T444E and 7.3L Power Stroke are medium duty engine platforms. Pickups, school buses, dump trucks, the engines have been used in a variety of diverse applications. • Over 2 million 7.3L Power Stroke engines are still in operation today, more than Chevrolet/GMC Duramax and Dodge Ram Cummins equipped pickups combined.

Scott Dyer
Scott Dyer

Best way to fix of that is to put it in the junk yard

Grey Wyman
Grey Wyman

dont get a 6.0l power stroke they suck get a 7.3

Brian Clark
Brian Clark

How many fixes does that crap motor need to have before you just say its just not worth it??

Jimmie Adcock
Jimmie Adcock

i agree 100 percent, ive never had any issues with mine and i roll it !!

Jimmie Adcock
Jimmie Adcock

its like they said you either got a good one or a lemon! thank god ive never had an issue with mine an i roll it!!

Richard Freeman
Richard Freeman

Ive replaced the head gaskets on plenty stock 6.0s and its not because of tuners. The injectors would last longer also if the owners would treat the fuel with some sort of lubricant to help stop stiction

Mike Jarvis
Mike Jarvis

I got a good fix, stay away from Ford powerchoke, Cummins is the way to go! Or Duramax, never seen a happy powerchoke owner.

Blu Heeler
Blu Heeler

I love my 6L! I did the egr delete already. Will eventually do the oil cooler. Has never left me stranded. Fun truck to have!

Kelsey Karns
Kelsey Karns

Thats why i own a 7.3 powerstroke i dont have little problems like that!

Joel Case Sr.
Joel Case Sr.

There's no fixn that p.o.s worked for ford truck dealer for years the 6.0 is junk

Matthew Lippa
Matthew Lippa

I'm over 300k no upgrades yet and I tow everyday. BAMM

Cedrick Desmarchais
Cedrick Desmarchais

Ford 6.0l Powerstroke solvers: take care of your damn truck and you wont have any problem...

John Forbes
John Forbes

Has a bed, Built on a truck frame..its a truck.

Jeff Weller
Jeff Weller

Love my 6.0 great engine when properly maintained,90k miles never a problem ,friend has one with 405k still going strong !

Kenny Muller
Kenny Muller

Any guy whos done real research on a 6.0 will realise what an easy fix they are to have a strong, durable motor. Amd the plus side is, is that all the idiots loom over them cause they hear rumor, so they are incredibly cheap to buy. $2k in aftermarket will get u 13 sec 1/4 and still get u 300k+ miles. Trust me. Aint my first 6.0 build..

Chad Finlayson
Chad Finlayson

The 6.0 was made over seas and it originally ran on kerosene that's why they have problems I still like them if you take care of them well they should run great

AJ Brumfield
AJ Brumfield

Worse diesel motor ever made!!! -Diesel Fleet Mechanic

Rodrigo Ruiz
Rodrigo Ruiz

Basura de 6.0 power stroke nadie lo quiere

Brian J. Eugenio
Brian J. Eugenio

To all the ones complaining about injectors. Very seldom do injectors ever go bad..you have a weak battery playing hell on the ficm or weak fuel pump...a good mechanic would check fuel pressure very first thing.then ficm voltage..a little word of advice add one quart 2 cycle oil to tank of fuel and never have a stiction issue..injectors very very rare failure..if your paying for multiple injectors that's not the problem. 1 out of 30 injector problems I've seen is an injector. It is usually weak ficm caused by low voltage due to a weak battery or fuel pump..and the one injector I try to get working by adding 2 cycle oil to free up unless it's actually broke internally..6.0 got bad name from poor mechanics that don't fix the real problem..

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