How to Make a 6.4 Powerstroke Bulletproof? Explained

“Bulletproof” is a buzzword among car owners, especially when having a 6.4 Powerstroke. They have become the highest benchmark of quality and durability of any engine. 

The most common problem that traditional and ancient car owners confront is engine failure after extended travels. You might have faced this problem after using your car for years. If so, then making the engine bulletproof is the first thing that comes to mind.

But how to make a 6.4 Powerstroke bulletproof? Do you need to hire a professional, or can you just do it yourself? We hope you will go through the easy steps I’ve mentioned below to get all your answers. 

What does Bulletproof Powerstroke Mean?

Bulletproof means that the engine performance is almost 100% reliable.

In 2009, a company called Bulletproof Diesel was started, which fixed many major problems with the 6.0L Power Stroke Diesel V-8 engine in Ford models from 2003 to 2007.

Since then, the bulletproof Powerstroke became the best performing and most reliable Powerstroke engine ever made.

How to Make a 6.4 Powerstroke Bulletproof?

A 6.4 Powerstroke can be stated to be bulletproof when it has covered at least four of five core issues. The significant issues are –

  • EGR cooler
  • Oil cooler 
  • Head studs
  • Fuel injection control module (FICM), and 
  • Water pump

The goal of bulletproofing a 6.4 Powerstroke issues related to the EGR valve and cooler and the oil cooler. It’s because, after a few years of use, the oil cooler gets blocked.  It also becomes clogged with the gunk. 

When the gunk is blocked, it creates obstacles, and the fluid flowing gets slow. As the oil cooler and EGR fail or lose their capabilities after a long period of use, problems with temperature arise. 

The fuel temperature gets high too quickly, increasing the possibility of engine failure and accidents. This makes the exhaust gases gush into the oil cooling function. As a result, it damages the gasket and the oil cooler. Hopefully, bulletproof diesel has improved.

Now oil coolers and EGR coolers have been developed into built-in coolers. 

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These new components are far better in performance and durability than the car’s old coolers.

In addition, it also needs the cement of high-end studs, FICM, and the water pump of your old car. You can claim your 6.4 Powerstroke to be bulletproofed by replacing all these.

I have listed down a step-by-step blueprint for making your 6.4 Powerstroke bulletproof. 

  • Tear up your engine
  • Find out  the problems
  • Replace  the components
  • Reassemble the engine

Step-1: Tearing Up

Your first task is tearing up the engine. Here you have to remove the faulty components and the parts that do not perform well. You also have to check other parts as they can be damaged after a few uses. 

The removal project should go through a systematic process. So, first of all, remove the oil cooler. The oil cooler is one of the most critical parts that are related to bulletproofing your 6.4 Powerstroke. 

Because the fuel in old cars heats up quickly, the cooler has to be updated or replaced. Changing the oil cooler will allow your vehicle a smooth and fast start. Users have experienced better speed than before. 

The next part you need to remove is the fuel filter. It becomes too dirty after prolonged use. So, the oil cooler gets blocked with the gasket and makes the work harder for you. It creates obstacles in the engine, so it takes more time to start. It can also create harsh rattling noise while starting. 

When you remove the fuel filter, you need to be careful. Because sometimes, the filter is just dirty, and all you need is to clean it properly. There is no need to replace it and invest extra money.  

Finally, it is time to remove the valve cover. The valve cover also gets dirty sometimes and stops working. It creates problems for the EGR valve directly. When your car is old, you may notice some tears or scratches. In such a case, you can just repair it without replacing it. 

Step-2: Find Out the Problem

Now look for the core components that are creating the problems. Removing the oil cooler, valve cover, and fuel filter will help you see other parts correctly.

Check every tiny part of the engine if there’s any problem. Though you need to replace only a few pieces to make your 6.4 Powerstroke bulletproof, you can solve other issues at a time.

It would be best to be careful when searching the problems with the oil cooler, EGR valve, gaskets, oil injectors, and EGR cooler. They are the significant components that create difficulties while bulletproofing. 

Step-3: Replacing the Components 

Now it’s time to replace the parts you have removed with bulletproof products. Sometimes you can just upgrade it into a new version and skip replacing it. Try to make sure that all the removed parts have a decent wash and that there is no dirt inside. 

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Many parts need to be replaced while bulletproofing. But the significant changemakers could be:

  • Oil cooler
  • EGR cooler
  • Head studs
  • Water pump
  • Fuel injection control module

Along with these parts, you can make changes in other parts to boost the engine performance, like radiators, intercoolers, exhaust gas systems, exhaust brakes, monitors, etc.

Step-4: Reassemble the Engine

Now put the parts in the engine and check if they fit correctly. You can see the bulletproofing task is done with just simple steps. But can you call it bulletproof yet? Well, to confirm whether it is finally bulletproofed or not, you need a test drive. 

Take a test drive and check a few things while and after a few drives. 

Time to Go for a Test Drive

Have a test drive to check the performance improvement and modifications. Observe the upgrades in the 6.4 Bulletproof Powerstroke. 

Before that, let me inform you that you can check these changes through a performance monitor, and there are also digital gauges for that. These two assure you that your can runs well and gives you comprehensive data about the temperature, engine performance, speed, and fuel efficiency. 

All you have to do is to install a performance monitor and digital gauges in your car. And now you can go for new experiences.  

What Brings in After the Ford 6.4 Bulletproof Upgrades?

Improvement of Lift Pumps

A bulletproof 6.4 Powerstroke gives you high performance with the lift pumps. 

They allow you to adjust the fuel pressure while driving, and you can experience a next-level ride. It controls the oil and gives appropriate pressure for all the instances. 

Cool Air Intake

Because of the cool air intake, you will experience smooth airflow as well as temperature resistance in a bulletproof Powerstroke. Plus, you will also get faster throttle speed and turbo spool-up. It makes your vehicles perfect for race or haul.

After bulletproofing your Powerstroke, the cool air intake makes the ride smoother and more engaging than before. 

Engine Cooler and Fuel Filtration Systems

Dirt has an awful effect on the cooler and causes several engine problems. The basic level OEM function doesn’t filter the dirt, sand, or metal contaminants. 

Bulletproof Engine Cooler and fuel Filtration System cleans up every minor contaminant and sand. Thus, all the internal components will stay safe from unwanted damage. 

Aftermarket Radiators

Your engine cooling system can be more efficient and long-lasting with aftermarket radiators designed for 6.4 Powerstroke. An aftermarket radiator is perfect if you want your cooler to stop draining and make a fresh change. 

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Tuners and Programmers

Tuners and programmers’ upgrades to 6.4 will give you an improved performance. It is convenient and adds a lot of extra power to your 6.4 Powerstroke.  It also increases efficiency, which makes the engine work more effectively.  

Oil Coolers

When your engine is finally bulletproofed, you’ll notice a significant improvement in the oil cooler. It will cool the fuel more efficiently than before. It will also assist you in controlling the excessive heat of the fuel.

After bulletproofing the engine, the users expressed that they hadn’t faced any unwanted accidents or engine damage. 

Exhaust Function 

Sometimes when we go for a long drive or drive a few times in a day, the exhaust function gets clogged or unavailable. But when your engine is bulletproofed, you don’t need to experience that anymore. 

In an improved Powerstroke, you will see the exhaust gas flow has increased. So, it will automatically help to balance the temperature and allows your engine to work under pressure.

Head Studs

We mostly face head gasket failures with an old or faulty engine. But when you make your Powerstroke bulletproof, you’ll get a heavy-duty head stud. This one helps the cylinder head to stay in place and work firmly.  

Exhaust Brakes

The traditional old exhaust brakes are very complicated to work with.  They often don’t function well while driving, so you have a high risk of engine failure. But in upgraded and bulletproof Powerstroke, it rocks without any difficulties. 


Can you Bulletproof 6.4 Powerstroke?

Yes, It is possible to make 6.4 Powerstroke bulletproof. Make the necessary adjustments that have been stated above, and you will be good to go.

Is a BulletProof 6.4 reliable?

Keep your 6.4 diesel in good condition and fix problems as they come up. With the right upgrades, the 6.4 Power Stroke can be turned into a much more reliable engine.

How many miles will a 6.4 Powerstroke last?

While truck enthusiasts typically criticize the 6.0-liter Power Stroke for its unreliability. Consumer Reports has listed, the 2008 6.4-liter as the pickup most likely to require a rebuild. Furthermore, it predicts that major repairs will take place between 65,000 and 119,000 miles.

Final Words 

Now you know how to make a 6.4 Powerstroke bulletproof. So, bid a long goodbye to sudden engine failure. Just replace the old components and install the new updates. And get superior performance and significant experience with your engine.

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Brian Polk

Brian is an automotive expert who has 12 years of experience in the industry. He has worked on a variety of cars, from high-end luxury vehicles to budget-friendly options, and has a wealth of knowledge on the subject. He is passionate about automobile and enjoys sharing his knowledge with others, whether they are looking to purchase a new motorized vehicle or simply learn more about the inner workings of these machines. In his free time, Brian enjoys working in his automobile workshop and spending time at the track.

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