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6.0 Bulletproof | Bulleting Proofing Your 6.0L Powerstroke

Vinny Himes



6.0 Bulletproof | Bullet Proofing Your 6.0L Powerstroke

I receive some really good emails from our customers here at Lead Foot Diesel Performance. I feel it is my responsibility to give them the absolute best reply that I can. There is a lot of information swimming around in my brain from playing with Diesel Trucks over the years. Some people in this industry choose to keep that information to themselves. I however enjoy educating my customer’s. So sit back, relax and learn about the 6.0 Bulletproof.

One of the most common questions I get asked is…

“What can I do to make sure my diesel truck will last for a long time and be reliable?”

That is such a great question and the answer varies from truck to truck. I just took an hour to reply to this question from a customer that owns a 6.0L Ford Powerstroke. I figured I would post the reply here and maybe it will reach and help many people instead of just one customer.

Here is a list of the parts we recommend here at the shop for our 6.0 Bulletproof customers wanting to do some preventative maintenance.

6.0 Bulletproof

Here you can see the casting sand from inside the engine in the lower radiator hose on a 6.0 powerstroke

As I explained over the phone the cooling system is the big scary monster under the bed, when it comes to the 6.0L Ford’s bad rap. The coolant filtration system will resolve that issue, I can’t guarantee your cooling system doesn’t already have some level of casting sand caught up in it, but we can do a good flush on it and then install the coolant filter and avoid any major failures down the road.

I would definitely do the EGR delete, not only is that a potential failure in the cooling system but it also pushed spent exhaust gasses and heavy soot through the intake manifold that should have nice cool CLEAN air flowing through it. It’s a horrible design and causes nothing but issues with the way your truck operates.  That’s why we have the 6.0 Bulletproof kit.

When going through the 6.0 Bulletproof the EGR delete kit is a very involved installation we have to remove everything from the top of the engine to remove the faulty EGR cooler and install the delete kit. We will replace all the factory intake gaskets as well as cleaning the intake manifold that is most definitely full of a mixture of diesel soot and oil. There’s no point in leaving all the gunk in there, the intake will flow much better once cleaned.

The regulated return kit and the FASS fuel system would be two aftermarket parts I really would like to see you get. These two parts will aid in the life expectancy of your injectors. The regulated return system will make sure all 8 injectors receive equal and adequate fuel pressure. For the most part when we see failed injectors on a 6.0 Bulletproof it is the rear injectors because they don’t see the same amount of fuel pressure as the forward injectors which is where the fuel comes into the cylinder head. The rear injectors get starved for fuel and that fuel is the only lubrication those injectors get.

6.0 Bulletproof can be a bit expensive, but learning all that is involved can give you some comfort when handing over your truck to the mechanics.  The regulated return system is a 12 hour job. We have to remove ALL of the factory fuel lines from the engine bay.  Then replace them with high flowing lines and install the regulator. Some of these fuel lines are located behind the factory exhaust up pipes. They require the removal of the up pipes along with a pile of other OEM parts.

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The FASS fuel system will replace your weak factory lift pump that’s located on the frame rail under the driver’s seat. It also replaces the factory fuel filters which are very messy to change. The FASS has two filters built into it, one is a 10 micron air water separator which the fuel flows through first. It then passes through a 2 micron fuel filter before going to the injectors. Nothing is going to get through that 2 micron filter, not even that grey lining found in the fuel tank on the Cab and Chassis trucks. The FASS comes with all new fuel lines from the tank all the way to the engine bay. It will flow twice as much volume as the stock fuel system and runs at a higher pressure which not only helps with performance because of better fuel atomization, but it will also help with fuel economy. Nothing phenomenal but it will go up a little. Keep reading to learn about the 6.0 Bullefproof.

We have to do a tuner to keep the check engine light from coming on after we delete the EGR. I have the SCT 5015 programmer on my personal truck because it has some very useful gauges built into it that you don’t get from the factory. This will come in handy when the truck gets more miles on it and other common wear items start failing. You will be able to diagnose the truck yourself which will speed up the repair process for us.

The billet water pump is a no brainer honestly. It’s the one engine part that can fail and lead to an overheat scenario. If that engine overheats you will crack the cylinder heads which will be a $6,000 repair job. Let’s avoid that by installing a $350 aftermarket water pump that can’t crack.6.0 Bulletproof

That is a pretty awesome list of parts and those parts will help you avoid thousands of dollars in potential repairs. If you want to replace the fuel tank with a glass lined tank it wouldn’t be a bad idea but may not be necessary just yet. With the FASS installed the potential damage that the tank lining could cause wouldn’t really be an issue. It could leave you stranded someday down the road but it wouldn’t hurt the injectors.

You had asked about an aftermarket intake and that will help with performance and fuel economy, it is by no means required to keep the truck from breaking down. I don’t want you to feel like that is something you have to do, but it will look nice and help with performance.

The tuner is going to produce more exhaust soot and that will clog up the catalytic converter over time you may have to get an aftermarket exhaust later on down the road which will eliminate the CAT.  All said and done, the 6.0 Bulletproof is a great option when your shopping around for your next diesel truck.

To Learn more, feel free to contact me at Lead Foot Diesel

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    08/25/2014 at 12:22 PM

    From my own personal experience, I can say that any Bulletproof Diesel product is worth its weight in gold… yeeesss… it is some how expensive, but not when you look at all you could potentially spend in engine repairs over and over again… DO IT ONCE AND DO IT RIGHT. Also, aren’t you tire of hearing from products and manufacturers “we do wonders!!” and it is all a pile of crab? Well, guess what!… BulletProffDiesel’s products really does what it says it does. And their customer services are extremely good… waaaay over the standard. Not to mention the most important part for me at least… it is MADE IN THE U. S. AND AN A.

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    10/29/2014 at 2:01 PM

    Oh the old 6.0L. We have a lot of trouble with head gaskets. Here is an article about how to know and test when your head gaskets might need replacing or blown.

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    Nick thompson

    07/05/2015 at 1:28 PM

    One more product also offered by bulletproof diesel is the bulletproof fan clutch adapter. I have had my truck overheat with the factory fan clutch doing absolutely nothing to help. A new factory fan clutch did not help either. So I replaced the factory visctronic clutch with the bulletproof diesel fan clutch adapter ($56) and a Hayden 2835 mechanical fan clutch. This is a dynamite combination for those of us that pull with our trucks. Also, it’s a great addition to the bullet proof water pump and can be done at the same time.

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    04/06/2017 at 7:27 AM

    I am interested in buying a Texas king ranch with

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