Welcome

By now I'm sure you all have heard about Bulletproofing the Ford 6.0 and 6.4 engines. If you own one it's inevitable, at some point you're going to have to replace the head gaskets , EGR and or oil cooler. So to help you through the process we've put together a step by step of the procedure we go through when Bulletproofing.

Step 1 :

The first thing we do is make sure the vehicle sits over night so we can check the injector readings while the vehicle is cold. The reason we do this is due to the fact we have to remove the injectors anyhow when performing a Bulletproof if the injectors are failing now would be the time to replace them since there is no additional labor time to do so.

Step 2 : 

We lift the cab (with the exception of E-series box vans and ambulances)! Once the cab is lifted we start the disassembly process. We remove the cylinder heads and Ray takes them to his machine shop to pressure test , resurface and do a valve job if necessary. This is where we start the cleaning process of the intake manifold, high pressure oil pump and oil cooler area as well as the top of the block. We also resurface the exhaust manifolds, we want to insure there is a clean and even surface for the new gaskets.

Step 3:

While we are waiting for the cylinder heads to come back we split the turbocharger open and start cleaning all of the carbon build up out. These turbochargers have variable veins inside and once the carbon build up gets to be too much the veins start sticking. 

Step 4: 

We start the reassembly process. All of our Bulletproof parts come straight from Bulletproof Diesel. We install the new OEM Ford head gaskets out of their kit and the new ARP head studs. Throw those head bolts in the trash! A lot of misconception we have heard over the years is that the head gaskets are the failure point on the Ford 6.0 when in reality it's the head bolts. The head bolts are a stretch to yield design so over time when they start stretching it causes the head gaskets to lift. The ARP head studs are the solution to this problem. The fuel injectors get new seals , new "dummy" plugs and stand pipes in the oil rails. High pressure oil pump quick disconnect delete gets installed. EGR 

Step5:

Installing the Bulletproof diesel EGR cooler and OEM oil cooler (unless you decided to upgrade to the Bulletproof Diesel oil cooler aka oil cooler relocation kit). Bulletproof Diesel has engineered a new design for the EGR coolers. Instead of having the finned core you will now have the welded tube core.

Step 6:

Once everything is reassembled we do an oil and fuel filter change all with OEM filters and Rotella 15W40 oil unless otherwise specified by the customer. We also install a SCT tuner that we set a tow safe tune on. We do not recommended adjusting the tuner any higher than 70hp unless the cylinder heads are fire ringed.