Which "solution" kit to get?
With lots of egr upgrade/delete, head gasket and oil cooler kits to choose from which is the best bang for the buck? Bulletproof diesel seems to offer a good kit with a lifetime warranty but are pricey. Sinister and alligator offer ones as well that are $500-$600 less. Performance machine mfg offers a good one with a limited lifetime warranty. Obviously for the ultimate in a fail proof oil cooler bulletproof is where you want to go but again, theirs is $1800 just for the cooler. Ive decided to stick with the ford style cooler but will go egr delete, arp head studs, etc. now which head gasket? Ford? Pmm? Black onyx (or whatever they are)? Anyone have any experience with any of these companys' products? Has anyone managed to get their product to fail and if so, how was the warranty/customer service?
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The kits are pricey you can buy the parts separate for less. Use factory ford gaskets with the studs. My black onyx gaskets and arp studs blew in less then 5k miles and i had my heads plained flat but they still blew.
I gotta say the BPD stuff is awesome! I know its spendy but I think its worth it if you plan on keepin your truck around. Fix it once...
Well since I always get asked what parts I would recommend and where to get them as well as prices and part numbers I figured I would compile a list of parts for people to choose from for their head gasket and stud jobs.
ARP Head Studs: 250-4202 - Let me know if I can help you out with these, stealth automotive $439
OEM Oil Cooler Rebuild kit: 3C3Z 6A642 CA- Order from sunrisefordparts.com $269.43 shipped
BPD Remote Oil Cooler Kit - Price varies depending on what options you choose.
KEEP IN MIND THAT THE IPR Gen 2 EGR delete is NOT compatible with the BPD oil cooler kit.
IPR Gen 2 EGR delete kit: SKU: EGD-60GEN2B- iprresearch.com $259.99 + shipping
IPR High Flow Coolant Filter: iprresearch.com $249.00 + shipping
2003 Glow Plugs (SHORT) need 8: 3C3Z 12A342 AA - sunrisefordparts.com $13.20 ea. $105.60 total
2004-2007 Glow Plugs (LONG) need 8: 4C3Z 12A342 AA - sunrisefordparts.com $11.27 ea. $90.16 total
2003 - 2004
Glowplug buss bar right side: 3C3Z 12A690 BA - sunrisefordparts.com $40.80
Glowplug buss bar left side: 3C3Z 12A690 AA - sunrisefordparts.com $40.80
2004.5 - 2007
Glowplug harness left side: 4C2Z 12A690 BA- sunrisefordparts.com $40.80
Glowplug harness right side: 4C2Z 12A690 AB- sunrisefordparts.com $40.80
Updated Turbo drain tube: 6C3Z 9T515 A - sunrisefordparts.com $24.37
Updated Turbo Oil feed: 3C3Z 9T516 A - sunrisefordparts.com $87.50
Thermostat: 4C4Z 8575 AA - sunrisefordparts.com $28.60
6.4 Banjo bolts: w302472 Need 2 - sunrisefordparts.com $10.50
6.4 banjo bolt washers: w303659 need 4 - sunrisefordparts.com $3.60
Main drive belt: jk8 1331 a - sunrisefordparts.com $49.82
Secondary drive belt: jk6 664 a - sunrisefordparts.com $25.34
Updated dummy plugs need 2: w302908 - sunrisefordparts.com $12.30 ea $24.60 total.
Updated standpipes need 2 (2003-2004.25): 3C3Z 6N853 BA - sunrisefordparts.com $51.60 ec $103.20 total. Not sure if headgaskets for the 03 come with the standpipe or not?? Checking on this and will update when I get the proper information.
Updated Standpipes need 2 (2004.5-2007): 6E7Z 9A332 A - sunrisefordparts.com $45.60 ea $91.20 total. Keep in mind new head gaskets come with 1 standpipe with each head gasket.
There is also a "kit" that has both updated dummy plugs (2) and both updated standpipes (2): 6E7Z 9A332 B - sunrisefordparts.com $111.60
18mm OEM Head Gaskets: 3C3Z 6051 CB need 2 - sunrisefordparts.com $147.60 each, $295.20 total for both. Comes with new updated standpipe, new gasket and head locating dowels (each gasket has one of each and 10 TTY bolts).
20mm OEM Head gaskets: 6C3Z 6051 AA need 2 - sunrisefordparts.com $271.20, Comes with new updated standpipe, gasket TTY headbolts and head locating dowels. Sunrisefordparts.com*
DEPENDING on the MY of your truck you will either have 18mm or 20mm heads.
Build date before Jan 17, 2006 you have an uncommonized engine with 18mm heads and dowels.
Build date after Jan 17, 2006 you have a commonized engine with 20mm heads and dowels.
Water separator updated drain kit: 6e7z 9c082 a - sunrisefordparts.com $12.50
OEM Oil Filter: FL 2016 - sunrisefordparts.com $19.50
OEM OIL FILTER NOT NECESSARY IF YOU BUY THE BPD OIL COOLER KIT.
OEM Fuel Filter Kit: 3c3z 9n184 cb - sunrisefordparts.com $49.95
Exhaust manifold gaskets: 6c3z 9448 a need 2 - sunrisefordparts.com $21.22
CAC boots both hot and cold side. RIFFRAFFDIESEL.com I paid $140 shipped. If your cold side CAC (intercooler tube) is black plastic than upgrade to the metal one. 6c3z 6c640 aa sunrisefordparts.com $115.08
Injector o-ring kit: 3C3Z 9229 AA need 8 - sunrisefordparts.com $31.68 (if you send injectors to Jesse Warren you don’t need this part)*
Fleetgaurd Restore and Fleetgaurd Restore + cooling system chemical flushes. Can get at local big rig truck dealers (they can order it) usually around $23-$30 a gallon, need one gallon of each.
Zerex EC-1 Rated ELC fully formulated coolant, 1 case* buy it at NAPA Part number is ZXED-1 usually between $13-$20 a gallon times 6 in a case.
Rotella T6 full synthetic oil
I would also suggest updated ported rockers OR at the very least new plastic fulcrums for them.
For the rockers here is the Part numbers and prices.
Combination need 6 of these, 4C3Z 6564 AA - $52.80 each $316.80 total for all 6 @ sunrisefordparts.com
Single Intake rocker need 2 of these, 3C3Z 6564 BA - $44.40 each $88.80 total for both @ sunrisefordparts.com
Single Exhaust rocker need 2 of these, 3C3Z 6564 AB - $44.40 each $88.80 total for both @ sunrisefordparts.com
I would suggest push rods since it’s apart. 8c3z 6565 b need 16- sunrisefordparts.com $64.80
Depending on mileage it may be a good idea to replace the Roller Lifters.
Roller lifters with plastic guide and 4 lifters, need 4 of these sets: 8C3Z 6C329 A - sunrisefordparts.com $52.80 a set, $211.20 total
ARP Ultra Torque Lube 10oz bottle with brush*
Fumoto quick drain valve for the oil pan F-111n
Fumoto quick drain valves for the block plugs F-108N*
Snap-on torque adapter tool for rear head bolt on driver side. SRD35 $55 + shipping
11/16 12pt 1/2” drive short socket for head stud nuts.
18mm 1/2” drive 6pt socket to remove head bolts.
Blue spring fuel pressure update: 3C3Z 9T517 AG - sunrisefordparts.com $57.60
Updated STC fitting for 2005-2007 trucks: 4C3Z 9B246 F $42 at sunrisefordparts.com
HPOP cover gasket: 3C3Z 6619 EA - sunrisefordparts.com $13.20
IPR screen update: 3C3Z 9H529 A - sunrisefordparts.com $30.00
IPR valve (2003-2004): 3C3Z 9C968 AA - sunrisefordparts.com $195.60
IPR valve if it needs replaced (2005-2007): 5C3Z 9C968 CA - sunrisefordparts.com $186.00 (can be found cheaper)
If doing head gaskets on a 2003 - 2004.25 I would suggest replacing the ICP sensor and pigtail as well while it is apart as it is buried under the turbo and it would be a quick swap while it is all apart. That and they are known to fail on these MY's.
ICP sensor (2003-2004): 3C3Z 9F838 EA - sunrisefordparts.com $114.00
ICP sensor (2004.5-2007): 4C3Z 9F838 A - sunrisefordparts.com $114.00
ICP sensor pigtail (also the same pigtail for the EBP sensor): 5C3Z 12224 A - sunrisefordparts.com $60.00
If you decide to replace the HPOP this is where I would get it (I got mine from here) it comes with the updated STC fitting as well as a new IPR valve and the HPOP (2005-2007 models come with IPR and STC fitting 2003-2004 only come with the pump).
2003-2004.5 HPOP: 3C3Z 9A543 AARM - sunrisefordparts.com has it for $564 +$150 core. Injectorwarehouse.com is $579.95 + $200 core charge.
2005-2007 HPOP: 5C4Z 9A543 A - sunrisefordparts.com has it for $666.00 +$150 core for the pump only this place is $599.95 + $75 core charge and includes the updated STC fitting and new IPR valve with updated screen.
If I forgot anything I will add it later lol.
Also here is a link to most of the parts/numbers anyone would ever need for their 6.0L incase I missed something that someone might need or want.
6.0 Parts List By FORD?INTERNATIONAL
And here is a link to my build thread showing how it is possible for one person to tackle this job in their driveway, by themselves, with limited tools AND wearing only FILPPY FLOPPIES, shorts and a tee shirt!
She's under the knife, My build thread. Lots' Pics.
Last edited by Tuscany; 01-13-2013 at 10:06 AM.
Head studs you can get anywhere, just find te best price.
The ipr gen2 egr delete is the best one out there, they're currently only available for 05-07 (I see you have an 04), but I have an inside source telling me the 03-04 gen2 will be released soon and is available with integrated coolant ports the be able to use the ipr high flow coolant filter (also highly recamended).
But yes as you stated the bpd oil cooler is the best option because it completely eliminates the oem oil cooler.
If you choose to run a egr cooler oposssed to delete both ipr and bpd make nice coolers
Well it takes twice as long because I have to go back and correct all the words this stupid phone auto "corrects"
And how do you know my name!?! Lol