How Much Does It Cost to Bulletproof a 6.0L Powerstroke – Everything You Need to Know!

Bulletproofing a 6.0 Powerstroke involves giving it an unequivocal amount of reliability. it goes a long way to fix the many flaws found in the Ford 6.0L Powerstroke engine. And this does not come cheaply. 

There are several parts of the Powerstroke that you need to bulletproof to achieve optimal performance and reliability. For each, the bulletproofing is done at different prices. bulletproofing the engine will cost you around $5000 to $11000, and this varies depending on the type of protection you are going for.

This article covers the cost matter to give you a general idea of the price points you should expect. 

How Much Does It Cost to Bulletproof a 6.00L Powerstroke?

Bulletproofing a 6.0 Powerstroke

The bulletproof diesel costs a ton of money. It always has to be coupled with its oil cooler since it works to lower the temperatures and thus spares the EGR cooler and injectors from premature failure. For all these and more, you will have to part with around $3000 to $5000.

This value will vary depending on several variables you may have on your car. With the price range in mind, you can plan accordingly.  

The entire process of bulletproofing a 6.0 Powerstroke takes 5 to 7 days. This means that there is a lot of labor that goes into it, hence the high price point. Usually, there are different areas that are addressed when it comes to bulletproofing. Below is some insight into the cost for each area. 

What Else Can I Bulletproof?

There are other areas that you can bulletproof in your car. 

Bulletproofing the Window

Many people have thought about bulletproofing their windows. This involves professionally installing a bulletproof window which undoubtedly costs a boatload of money. The price tags range between $3000 to $5000—and this is for minimal protection. If you want to have it increased, the prices go up from $15000 to $20000. 

Oil Cooler Bulletproofing

The expenses keep increasing with every part you decide to bulletproof, and the oil cooler does not make it any easier. Bulletproofing the oil cooler is considered to have two main benefits; it lowers the temperature and reduces the chances of failure of the EGR cooler and injectors. These benefits do not come cheaply, it will cost you $3000 to $3500 so they can be installed. 

Bulletproofing a Tire

The tires offer no reprieve either. In this case, we are not thinking about the average tires—consider a 35% to 200% increase. Generally, the run-flat type of tires go for around 200 to $900. This makes the overall cost of bulletproofing range between $800 to $3600 on average. 

Bulletproofing FICM

Truth be told, the factory version of the Ford FICM consists of using a poor soldier. Thus, the resistors tend to shale loose with time. This will, in time, lead to issues such as an erratic engine. Therefore, bulletproofing the FICM is the way to go. The only issue will be over-voltage engine codes; hence you will need a timer after upgrading. 

Bulletproofing the Engine

Upgrading to a bulletproof engine is no easy feat, cost-wise. You will incur high costs of around $5500 to $11000—the exact value will depend on the type of protection you are going for. 

Bulletproofing the Gas Tank and Panel

Each panel is likely to cost you around $450 to $1000. The price will depend on the style of the panel you prefer—there are some that cost over $1500 each and offer solid heavy-duty paneling performance. 

For the gas tank, if you are going for self-sealing or fortifying, this will be around $2000 to $4500. Again, this cost depends on several factors such as the material you choose and gas tank selection. It costs even more if you opt for a professional to perform the installation.  

What Is Needed to Bulletproof a 6.0L Powerstroke?

Bulletproofing a 6.0l Powerstroke is a lengthy process. For optimal performance, you need to address at least 4 of the 5 most important areas since they tend to show issues. These parts include the water pump, the oil cooler, the EGR cooler, the head studs, and the fuel injection control module (FICM). 

How Long Does a Bulletproof 6.0 Last?

Bulletproofing a 6.0 Powerstroke is expensive for a good reason. It will last you not less than 500,000 miles without any issues. With proper maintenance, it is likely to last longer. 


You may have successfully removed the EGR cooler, but experts still insist on leaving the valve plugged in. Alternatively, you should consider leaving the valve at its stock location. If you unplug the valve or turn it off, you are likely to cause further problems. This often occurs in high boost levels. 

To know whether the EGR cooler is removed, you can check the passenger-side intake manifold. If there is a J-shaped metal tube from the intake manifold towards the turbo beneath the oil cooler cover, then the EGR cooler is removed. 

Typically, head studs are a must-have when it comes to upgrading the 6.0L Powerstroke. The head studs are usually heavy-duty and provide a high amount of strength. They serve to ensure that the vehicle’s cylinder head is not easily lifted with high combustion pressure. Since the head studs are strong, they use their accolade clamping force to restrict the lifting. 

Final Words

If you are thinking of bulletproofing your 6.0 Powerstroke, it is important to have a clear idea of the price. However, the prices above are a broader assessment since they tend to vary with several factors. But with that, you can know what to expect. 

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