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How To Make A 6.4 Powerstroke Bulletproof? [ Step By Step Guide ]

How To Make A 6.4 Powerstroke Bulletproof? [ Step By Step Guide ]

If your car has a 6.4 Powerstroke, you might already be familiar with the term ‘bulletproofing’ it. While considering the durability and quality of any automobile engine, you would come across this buzzword.

Traditionally, car owners encounter different types of issues with the engines, including failures. This mostly happens when they use the cars for extended travel. So, after years of delivering diligent service, your engine might have given way.

In case you want to know how you can make a 6.4 Powerstroke engine bulletproof, we have the right solution. In this article, you will get to know the right process for bulletproofing your 6.4 Powerstroke engine.

What do you mean by a bulletproof Powerstroke?

In a nutshell, making a Powerstroke engine bulletproof means making it completely reliable. The nomenclature dates back to 2009, when a company named Bulletproof Diesel started working on major issues in 6.0L Power Stroke Diesel V-8 engines.

This was mostly for the Ford models that the manufacturer launched between 2003 and 2007. Since then, Powerstroke engines with reliable performances got the reference ‘bulletproof’.

Therefore, bulletproof implied delivering the best performance and reliability standards in the engines. Over the next decade, bulletproof Powerstroke emerged as the best benchmark for any Powerstroke engines for their reliability and performance.

How to make a 6.4 Powerstroke bulletproof?

In case your engine has overcome at least four of the most common issues, you can deem it to be bulletproof. These five technical glitches include issues with the oil cooler, EGR cooler, head studs, water pump, and fuel injector control module. The fundamentals of making the engine bulletproof lie in addressing the issues related to the oil cooler and the EGR.

When you continually use your car, the oil cooler accumulates gunk and develops a clog. This gunk then results in a blockage and restricts fluid flow to the EGR cooler.

As the temperature of the fluid significantly rises, it results in a burst. As a result, the gasses get into the cooling system at a high force and damage the gasket.

Bulletproof Diesel has come up with an EGR cooler and an oil cooler capable of replacing the coolers that come built-in. In terms of durability and performance, these parts prove to be superior.

Besides, you need to switch to sophisticated FICM, a water pump, and better head studs. You can make your engine bulletproof when you upgrade to all these superior components.

Here’s a detailed overview of what it takes to make your car’s engine bulletproof.

1. Tearing up

In the first place, you need to tear up the engine. This implies that the engine should have no faulty parts or components that perform badly. Besides, you need to inspect other car parts for damage and replace them. Experts recommend following a systematic approach when you tear up the engine.

So, you need to start with the oil cooler removal. This happens to be one of the most important parts when it comes to bulletproofing your 6.4 Powerstroke.

In older models, the fuel tends to heat up pretty fast. Therefore, you need to replace or update the cooler. The car would enjoy a smooth start when you replace the oil cooler. So, you would appreciate the enhanced speed in your vehicle.

Next, you need to do away with the fuel filter. With continual use, the fuel filter accumulates dirt and leads to clogs. When the gasket blocks it, it would lead to obstacles in the car’s engine.

Eventually, it would take more time to get started. Besides, you would hear some rattling noise in the engine. Be extra careful while removing the car’s fuel filter. In case it has dirt accumulated on it, make sure to clean it at the beginning.

Lastly, you need to get the valve cover removed. This component also gets dirty and eventually stops functioning sometimes.

This causes some direct problems in the EGR valve. In case you have an old car, you would notice some scratches and tears. In these situations, you can go for a repair rather than completely replace it.

2. Detect the issue

At this stage, automobile owners need to look out for the factors triggering the issues. You can better view the internal parts when you remove the valve cover, oil cooler, and fuel filter.

Make sure not to overlook any part of the engine in case you face a problem. Making your 6.4 Powerstroke bulletproof would require you to replace only some of the components. However, it makes sense to address other possible issues during this time.

So, you need to look out for issues with the EGR valve, oil cooler, gaskets, EGR cooler, and oil injectors. Problems in these components might hamper the bulletproofing process.

3. Get new components

So far, we have recommended removing some parts in order to make your engine bulletproof. So, now’s the time to install new components to upgrade the system to a more powerful mechanism.

The replaced parts should be clean when you integrate them into your vehicle. Also, you need to replace some other parts during bulletproofing.

These include the EGR cooler, oil cooler, water pump, head studs, and the fuel injector control module. At the same time, you can replace other parts like the exhaust gas systems, intercoolers, radiators, monitors, and exhaust brakes to leverage the performance of the engine.

4. Get the engine reassembled

Lastly, you need to reassemble the engine, integrating the right parts in the right place. So, you can easily bulletproof your engine. Now, you need to test drive your car to examine whether or not you have really made it bulletproof.

What benefits do you get after making the upgrades?

After you make the 6.4 Powerstroke engine bulletproof, you can benefit in several ways.

1. Better lift pumps

The lift pumps in your car would be of better quality and deliver high performance. This would enable the driver to make necessary adjustments in the fuel pressure during driving.

Eventually, you would experience an elevated standard of rides. This is because the upgraded components would have a better level of control over the fuel pressure all the time.

2. Fuel infiltration system and engine cooler

When it comes to engine coolers, the accumulation of dirt can significantly rob them of their performance. With the basic level OEM, you won’t have an issue with filtering the metal contaminants, sand, or dirt.

When you make the engine bulletproof, the fuel filtration mechanism would clean up the minor contaminants like sand. Therefore, the internal parts of your car would remain secure from damage.

3. Cool air intake

The engine of your vehicle would take in cooler air than what it used to do before. This ensures a smooth airflow in a bulletproof Powerstroke engine.

It would also lead to better temperature resistance. The throttle speed would be faster, and the turbo spool-up would be better. This makes the car ideal for haul or races.

When you make the Powerstroke bulletproof, the rides would be smoother due to the intake of cool air. The engine would turn out to be more engaging than before.

4. Digital gauges and performance monitors

After installing digital gauges and performance monitors, you would find that your car is performing just as you expect it to. This would help you check different performance parameters and the temperature. Accordingly, you can elicit the best experience by tuning the car.

5. Aftermarket radiators

You can boost the efficiency of the cooling system and boost the durability of the components by installing aftermarket radiators. These components are specifically available for the 6.4 Powerstroke engine. So, the radiators would help you bring about viable changes to prevent the coolant from draining.

6. Programmers and tuners

Upgrades in the programmers and tuners of the engine would help you enhance the vehicle’s performance. These features would help the engine achieve additional power. This would also leverage the fuel efficiency of your car. After bulletproofing the engine, you would notice a significant upgrade in terms of performance.

7. Replacement up-pipes

The quality of the inbuilt up-pipes in the new version of the engine would be far better. They would ensure extended performance in the coming years. Most importantly, they don’t easily sustain damage or cracks.

8. Oil coolers

When you make your engine bulletproof, there would be a significant betterment in the performance of the oil cooler. This ensures that the fuel would remain cool for extended hours, and the performance would be better than before.

This would also help in mitigating the extra heat of the fuel. Once you make the engine bulletproof, you wouldn’t have unwanted accidents or damage in the engines.

9. Exhaust function

You must have noticed the exhaust function becoming unavailable or clogged when you frequently take your car for long drives. After you make your engine bulletproof, you won’t have this poor experience any longer.

The upgraded 6.4 Powerstroke engine would significantly increase the exhaust gas flow. This would help achieve an equilibrium between the temperature and enable the engine to perform well under high pressure.

Are deleted 6.4 reliable?

Yes indeed. A deleted engine with 6.4 Powerstroke proves to be reliable enough. When you delete the emission system, there would be a noticeable increment in the car’s gas mileage and power.

Can you make a 6.4 Powerstroke reliable?

When you consider the average performance and reviews of the 6.4 Powerstroke engine, you would receive lots of criticism. Therefore, you need to make the engine reliable by making it bulletproof. This ensures that the engine would be reliable, provided you maintain it properly.


Once you make your engine bulletproof, it can easily last more than 500K miles without facing any issue.

However, the reliability and mileage of a bulletproof engine largely depend on the engine and model. Most importantly, the dependability of a bulletproof engine also relies on the kind of servicing and maintenance it receives.

Many car owners do not rely on stock engines in branded cars as they tend to break down frequently. Therefore, it makes sense to bulletproof your 6.4 Powerstroke engine.

Whether your car is old or new, you can make the necessary upgrades if you can maintain it well. Making your engine bulletproof would involve a significant investment.

However, considering the strategic benefits you would enjoy in the coming years, it makes sense to bulletproof your 6.4 Powerstroke engine.