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Proper Cooling; Installing Bullet Proof Diesel’s New Oil Cooler System on a 2010 Ford F-350

Beat the Heat

John Lehenbauer
May 16, 2017
Photographers: John Lehenbauer
A high susceptibility to becoming clogged and restricted is an ongoing problem for the stock oil cooler on 6.4L Ford Power Stroke engines. The coolers are notorious for causing oil temperatures to run on the high side, which, if left unresolved, can cause major engine damage. The biggest issue with replacing the cooler is the difficulty in accessing it. On the ’08-to-’10 6.4L, the cooler is located in the valley of the block, under the turbocharger and almost every other component on the engine. Replacing the stock cooler requires a tremendous amount of labor, and it may need to be done many times throughout the truck’s lifetime.
This is where BulletProofDiesel’s Oil Cooler Relocation System comes into play, as it moves the oil cooler and filter away from the engine.
Photo 2/35   |   Here is the 6.4L Ford Power Stroke engine before dismantling begins. The truck’s cab and many parts and accessories have to be removed in order to access the stock oil cooler. It is recommended that a coolant flush be performed before tearing the cooling system apart, ensuring contaminants do not get into the new cooler.
A new OEM cooler and adapter are mounted under the brake master cylinder for easier access in the event of a problem. Another benefit of moving the oil cooler is that the new location allows ambient air to help cool it. In the valley, the unit is solely reliant on coolant and the block to regulate temperature. The other major components in the kit are the adapter and lines that facilitate moving the oil filter housing from the top of the engine to a location under the truck for easier maintenance.
Installing the BulletProof Oil Cooler Relocation System on a 6.4L Ford–powered rig is not a five-minute job. Like many engine-associated Super Duty upgrades, it requires removing or lifting the cab to improve access to the top and back of the engine. The system is a great replacement for a faulty stock cooler or when installed as a preventative measure with other scheduled service.
The ’10 Ford F-350 shop truck at Devil Mountain Diesel is the rig we’re using for this project. Read on through the following photos and captions, as DMD owner Jason Loeliger shows us how the system is installed.
Photo 3/35   |   Jason Loeliger of Devil Mountain Diesel in Walnut Creek, California, has removed a cab or two over the years. He likes to start by making sure all the body mount bolts can be removed easily.
Photo 4/35   |   If the front bumper is stock, it can remain on most trucks for this particular project. However, since our project truck has a large aftermarket bumper, Jason decided removing it would make the job easier.
Photo 5/35   |   Bulletproof Diesels Oil Cooler System Intercooler Removal
Photo 6/35   |   With the front bumper removed, Jason peels back the layers to get to the front of the engine.
Photo 7/35   |   Separating the body from the frame requires Jason to remove the master cylinder from the hydro-boost unit. He must also remove the pressure lines that are to the right of the master cylinder.
Photo 8/35   |   Once everything is unbolted and removed, the cab is lifted off the frame. Jason secures the body to the lift with tie-down straps to make sure it doesn’t shift.
Photo 9/35   |   After partially lifting the cab, Jason visually inspects the engine bay and underside to make sure everything is disconnected and clears the body.
Photo 10/35   |   Looking at the back of the engine after the cab is removed, it is easy to understand why most mechanics prefer raising the cab to access the turbocharger.
Photo 11/35   |   After the downpipe and exhaust plumbing are removed, the turbo is extracted from the engine’s valley.
Photo 12/35   |   Accessories on the front of the 6.4L are removed to gain access to the intake manifold, the final the piece of hardware that prevents removing the oil cooler.
Photo 13/35   |   Bulletproof Diesels Oil Cooler System Top Engine Cooler Turbo Mount
Photo 14/35   |   With the intake manifold out of the way, the oil cooler and turbo mount are removed.
Photo 15/35   |   BulletProofDiesel’s oil-cooler system includes coolant and oil hoses, along with the new adapter and oil cooler, and all of the fittings, mounting hardware, gaskets, and remote oil-filter mount, each individually sealed..
Photo 16/35   |   Once the proper O-rings are installed on the adapter, Jason starts the assembly process.
Photo 17/35   |   Bulletproof Diesels Oil Cooler System Factory Manual
Photo 18/35   |   It is important to torque all hardware to the proper specifications and in the correct sequences. Jason references his Ford service manual to get all the correct torque values.
Photo 19/35   |   As a rule of thumb, the oil-pressure sensor should be replaced any time a new oil cooler is installed.
Photo 20/35   |   Bulletproof Diesels Oil Cooler System Torque Wrench Turbo
Photo 21/35   |   With the turbo back in place, Jason torques the mounting hardware to specifications and begins the daunting task of putting everything else back together.
Photo 22/35   |   Once the turbo, downpipe, up-pipes, EGR, and fan are reinstalled, the cab is lowered back down onto the frame in order to continue.
Photo 23/35   |   After installing the oil-cooler’s mounting bracket, the master cylinder is secured to the hydro-boost.
Photo 24/35   |   Jason adds the silicone coolant hoses to the oil cooler before installing it on the master cylinder bracket.
Photo 25/35   |   The new oil cooler is mounted directly below the master cylinder. This location makes it accessible through the wheelwell liner and improves its cooling ability, since it’s now further away from engine heat.
Photo 26/35   |   The oil filter adapter and mounting bracket are assembled before being installed on the three studs located on the driver side, outside of the framerail.
Photo 27/35   |   Bulletproof Diesels Oil Cooler System Top Oil Cooler
Photo 28/35   |   Bulletproof Diesels Oil Cooler System Cooler Line Engine Master Cylinder
Photo 29/35   |   With the oil cooler and filter mounted, the braided lines are connected with the adapter plate on the top of the engine. Four variable-length, premade hoses are provided in the kit.
Photo 30/35   |   Once the oil lines are in and secured, the front of the truck and engine bay is reassembled.
Photo 31/35   |   A small bracket to secure the silicone coolant hoses to the back of the fuel cooler is included.
Photo 32/35   |   The last part of the installation is securing the coolant hoses to the adapter. This is done last so the hoses can be routed around engine accessories.
Photo 33/35   |   It is important to make sure all the body bolts are secured properly.
Photo 34/35   |   The only visible signs of the new oil cooler in the engine bay are the standout blue silicone coolant hoses and the more subtle black oil lines.
Photo 35/35   |   Bulletproof Diesels Oil Cooler System Front Driver Side


Bulletproof Diesel
Mesa, AZ 85210
Devil Mountain Diesel