This BulletProof Oil Coolers are designed to replace several components that are prone to failure or degradation on 2003 through 2007 models of the F-Series and 2003 through current E-Series models equipped with the 6.0L Navistar/Power Stroke Diesel engine.
The Problems with the OE Engine Oil Cooler
There are several issues that begin inside the oil cooler. The first problem has to do with the design of the oil cooler itself. A cut-away view of the oil cooler (see Figure 2) shows the close proximity of the oil and coolant levels populated by large numbers of fins, which makes for an excellent heat exchanger. It also shows just how tight and small the passages for the fluids are, making them susceptible to obstruction.
Figure 2: 
The second issue has to do with the cooling and filtration of the engine oil. The oil filter is placed AFTER (or downstream from) the oil cooler. This has the effect of making the oil cooler the primary filter, allowing it to catch and plug with debris. The debris hinders oil flow through the cooler and thus to the rest of the engine. It also decreases the efficiency of the heat transfer from the oil to the coolant.
The third issue occurs within the coolant section of the engine oil cooler. Cooling system solids and debris can deposit in the intricate passages of the coolant section, restricting the flow of coolant through the cooler. Any restrictions in either the coolant or oil sections of the engine oil cooler will result in less than optimal heat transfer.
The fourth issue is evident when the integrity of the oil/coolant barrier is compromised. When this barrier is compromised, oil and coolant will mix. Normally, the first symptom of this happening is oil in the coolant (degas) bottle. The Domino Effect of the OE Engine Oil Cooler The four engine oil cooler issues can have a domino effect on other 6.0L components. The secondary issues common on the 6.0L Power Stroke engine include:
• EGR Cooler Failure
• Premature Injector Failure
• Engine Oil break-down due to high temperatures
• Early Engine Wear due to Poorly Conditioned Engine Oil
How the Bullet Proof Oil Cooler Kit Works
The BulletProof Oil Transfer Block (patented) replaces the OE engine oil cooler. The oil transfer block mounts where the OE oil cooler mounted and it utilizes OE gaskets and hardware to retain the assembly to the engine.
Engine oil is directed through extreme duty hose, first to the oil filter assembly (if equipped with remote oil filter) and then to the air-to oil cooler. The supplied oil filter is much larger and is rated for almost twice the oil flow before bypass than the OE oil filter element. This eliminates the pattern failure of a plugged or restricted oil side of the engine oil cooler, early engine wear due to poorly filtered oil and early injector failure due to poorly filtered oil.
Since the engine oil filter is a remotely mounted “spin-on” filter, the need for an oil filter housing drain valve is eliminated. This eliminates the pattern failure of an immediate or delayed catastrophic loss of oil pressure due to a faulty oil filter housing drain valve.
To maintain or exceed OE engine oil heat removal, an effective liquid to air heat exchanger needed to be utilized. Further, this new engine oil cooler needed to have sufficient air flow to maximize heat transfer.
The supplied engine oil cooler is mounted just behind the condenser. The oil cooler is in direct air for maximum heat transfer. The radiator fan also acts to move air through the oil cooler. Even during extended idle with little to no air flow, the radiator fan moves more than enough air through the oil cooler to effect more than sufficient heat transfer. This eliminates the pattern failures of early injector failure and early engine wear due to overheated engine oil. This also cures the pattern failure of coolant and oil mixing because of a compromised oil/coolant barrier. This system also has the added benefit of liberating the engine oil temperature from the coolant temperature. This means that during cooler seasons, engine oil temperatures can run cooler than can be accomplished with the OE engine oil cooler. Another benefit of this system is the separation of the oil coolers reliance on the engine coolant for heat transfer. Since the OE oil cooler is the highest point in the cooling system, a low coolant condition could effectively render the OE oil cooler inoperative.
The oil then travels from the supplied oil cooler back to the Oil Transfer Block. The now fully filtered and cooled oil is then directed to the various oil circuits. The oil transfer block has an integrated High-Pressure Oil Pump (HPOP) filter screen. This screen is constructed from stainless steel and will last the life of the engine. This cures the pattern failure of the High-Pressure Oil Pump (HPOP) filter screen failing, resulting in the HPOP failing.
