Best parts for rebuilding a Ford 6.0? Need recommendations

Seeking Help
1

Hi everyone, after a lot of back and forth, I’ve decided to rebuild my 6.0 instead of buying a new truck.

I’m looking for advice on what brand oil cooler and EGR cooler to go with. I know ARP studs are the go-to for the heads. Some people swear by Motorcraft parts, others say go with Bulletproof. I’ve even heard people say the Bulletproof EGR isn’t worth it. What’s your experience?

I’ve already replaced the HPOP, oil cooler, and EGR cooler before, so I’m comfortable doing all the labor myself, including lifting the cab. My goal is to make the truck as reliable as possible, so I plan to swap everything out at once.

2

I’d go with a Bulletproof EGR cooler and an OEM oil cooler. Or you could just weld a plug on the EGR.

3

Darian said:
I’d go with a Bulletproof EGR cooler and an OEM oil cooler. Or you could just weld a plug on the EGR.

I can weld a plug, and I was considering that. Would it throw codes or fail smog? It’s a 2006, and I’m in California.

4

@Wylie
Most common tunes can turn off the CEL.

5

Merlin said:
@Wylie
Most common tunes can turn off the CEL.

That doesn’t work in California anymore.

6

@Wylie
I’d leave the EGR in place. I moved from California to Texas and had the Bulletproof EGR installed when I was in California. The Bulletproof one solves the problem the stock EGR had.

7

Darian said:
@Wylie
I’d leave the EGR in place. I moved from California to Texas and had the Bulletproof EGR installed when I was in California. The Bulletproof one solves the problem the stock EGR had.

I checked out Bulletproof Diesel’s website, and I’ll probably go with their EGR and oil cooler combo. Thanks for the advice—helps me narrow it down!

8

@Wylie
Starting in 2024, California requires a functional EGR. Before that, you didn’t need EGR monitors set. I’m getting a Bulletproof Diesel EGR installed this week.

9

You’d get better info on forums like powerstroke.org or ford-trucks.com. There’s a ton of reading there, but if you stick to this forum, you’ll probably get a mix of good advice and sarcasm.

10

@Cameron
This guy knows what he’s talking about.

11

@Cameron
Thanks, I’ll check those out. I figured I’d get a mix of answers here. My dad’s had this truck since new, and I don’t want to spend $1,000+ a month for a new truck to tow a trailer a couple of times a year. Appreciate the direction!

12

Just buy a new truck. Trust me—you’ll thank me in five years. I’ve tried rebuilding twice, and it was a waste of money both times.

13

I’m running a Bulletproof Diesel external oil cooler after going through multiple bad OEM ones. My EGR cooler is completely deleted. I’ve got ARP studs, and the truck runs perfectly.

14

Vick said:
I’m running a Bulletproof Diesel external oil cooler after going through multiple bad OEM ones. My EGR cooler is completely deleted. I’ve got ARP studs, and the truck runs perfectly.

Do you have to smog your truck? I want to delete mine but worry about throwing codes. Mine’s an ‘06.

15

@Wylie
I don’t need to smog my truck in Florida. I have an ‘05, and I assume my tune clears any codes.

16

Vick said:
@Wylie
I don’t need to smog my truck in Florida. I have an ‘05, and I assume my tune clears any codes.

From what I’ve read, the ‘05 isn’t as affected by an EGR delete. I’ll probably delete mine but keep the Bulletproof EGR as a backup in case I need it for smog.

17

@Wylie
Interesting, I didn’t know that!

18

You can use freeze plugs to fix your OEM EGR cooler. Bulletproof still sells their legit, non-Chinese-made oil coolers. Just make sure to backflush properly, or you’ll be doing it again.

19

Cai said:
You can use freeze plugs to fix your OEM EGR cooler. Bulletproof still sells their legit, non-Chinese-made oil coolers. Just make sure to backflush properly, or you’ll be doing it again.

I’ll give that a try. If it throws codes, I’ll just buy a new EGR cooler and reinstall it.

20

@Wylie
If you plug both sides of the EGR cooler, you’ll need a tune to avoid a P0401 low flow code.