Bullet Proof Diesel 6.0 Powerstroke Oil System Upgrade (All Climate) – Part #90404003

Upgrade one of the most critical weak points on your 2005–2007 Ford 6.0L Powerstroke with this complete All Climate oil system from Bullet Proof Diesel. The factory liquid-to-liquid oil cooler is a well-known failure point that can clog, restrict coolant flow, overheat oil, and lead to EGR cooler problems, injector issues, or even oil/coolant mixing. This kit replaces that internal cooler with a robust, front-mounted air-to-oil heat exchanger while also converting the oil filtration to a simple, reliable spin-on design.

The All Climate version includes a patented thermostat that lets oil reach proper operating temperature quickly in cold weather by bypassing the cooler until it’s warm, then delivering full cooling capacity in hot conditions or under heavy load. The result is more consistent oil temperatures whether you’re commuting in winter, towing in summer heat, or running in extreme environments.

A CNC-machined billet aluminum transfer block replaces the factory oil cooler and filter housing in the engine valley. Oil is routed through heavy-duty hoses to a remote spin-on filter (compatible with common Wix, NAPA, and similar filters) and then to the large air-to-oil cooler typically mounted behind the A/C condenser. This design eliminates the problematic OEM filter housing, improves filtration, and keeps oil cooler for the high-pressure oil pump, injectors, and engine.

The system has been real-world tested in demanding conditions from desert heat to sub-zero cold. It is intended for heavy-duty use, towing, and owners who want greater long-term reliability from their 6.0L Powerstroke.

Key Features

• Air-to-oil cooler replaces the failure-prone OEM coolant-to-oil cooler
• Patented All Climate thermostat for proper warmup in cold weather and strong cooling in heat
• Upgraded spin-on oil filter system for simpler, more reliable filtration
• Billet oil transfer block with heavy-duty hoses and hardware
• Helps maintain optimal oil temperature under load and in varied climates
• Designed for 2005–2007 Ford Super Duty trucks with the 6.0L Powerstroke

Fitment Notes Fits 2005–2007 Ford F-250, F-350, and similar Super Duty models with the 6.0L Powerstroke. Not compatible with E-Series vans or most tilt-cab applications. Designed for factory bumper; aftermarket bumpers may require an additional bracket. Verify your A/C condenser and power steering cooler configuration before ordering, as additional components may be needed for proper installation.

This upgrade is widely regarded as one of the most important reliability modifications for the 6.0L Powerstroke. It addresses a core factory limitation while adding easier maintenance and better oil control across a wide range of operating conditions.