Things To Know About Bulletproof 6.0

Have you ever heard of “Bulletproof 6.0 Powerstroke diesel kit”, "Bulletproof truck", or "Bulletproof Ford 6.0L Engine"? Unfortunately “Bulletproof” is ambiguous with no clear definition. The term Bulletproof originates from Bulletproof Diesel, a parts and service shop in Mesa, Arizona. Bulletproof Diesel became famous for making aftermarket Exhaust Gas Recirculation coolers for Powerstroke 6.0L Diesels. They have since added aftermarket oil coolers, water pumps, fuel injection control modules (FICMs), and other aftermarket parts.

Unfortunately, Bulletproof Diesel quickly lost control of their branding and “Bulletproof” generically referred to an upgraded 6.0 engine kit, which often consisted of a built motor. 2003-2007 Ford 6.0L diesel engines generally have a bad reputation. A lot of early customers suffered blown head gaskets and sought help from Ford under warranty. In an effort to improve things, Ford dealerships replaced the head gaskets only to have the engines melt down again. This is where “6.0Ls are junk” myth began.

It is only when the Ford engineers took a step back that they realized that the head gaskets were simply the breaking point in a chain of failures that had started with the oil cooler. Ford went on to build the factory oil cooler that had very small channels. Smaller channels had more cooling capacity with a similarly high propensity to clog. As particulates built up from the sand-casted parts, the coolant passages block in the oil cooler.

This blockage starves the Exhaust Gas Recirculation cooler. The Exhaust Gas Recirculation cooler chills hot exhaust gases, but when water fails to reach the cooler from clogged upstream channels, it quickly overheats. The overheating Exhaust Gas Recirculation breaks apart and dumps coolant into the intake. For the final straw, the cylinder head pressure with extra water is so high, something that causes the cylinder heads to float and the head gasket is destroyed.

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