There are several reasons that consumers are looking to replace parts in their Ford 6.0L Powerstroke turbo-diesel engines, built by Navistar. Reasons for replacement include the many issues with this engine made known to the public soon after its initial release in 2003.
Those who have used this engine have faced issues including stuck turbos, poor injectors, blown head gaskets, cracked EGR coolers, and more.
On average, consumers can expect to pay roughly $565 to replace a 6.0L Powerstroke turbo-diesel engine. This cost includes parts and labor, with the average cost of parts ringing in around $230 and the average cost of labor ringing in around $235.
Do note, however, that turning this into a DIY installation can save you several hundred dollars.
In this guide, we’ll break down the costs of replacing the Ford 6.0L engine’s oil cooler, including details about what parts and components you need to replace it.
We will compare the cost disparities among DIY replacement and professional replacement, as well as the benefits of replacement and ways to save money on this repair project.
- Cost Breakdown
- Cost of a 6.0L Powerstroke Oil Cooler Replacement Kit (Quotes)
- Cost of a 6.0L Powerstroke Oil Cooler Replacement (Including Installation)
- What Is the Cost of Replacement Long-Term?
- Benefits of Replacing Your Engine’s Oil Cooler
- How to Save Money on Your Oil Cooler Replacement
- Related Guides
To break down the costs of this replacement part, we’ll compare the different costs associated with buying the replacement as a kit vs. buying the parts and including the service cost of having a professional install it.
Cost of a 6.0L Powerstroke Oil Cooler Replacement Kit (Quotes)
For DIY installation, which can save you a lot of money, consider the average cost of the oil cooler replacement kit, which we have determined after gathering quotes from several major retailers/sellers of this product kit.
Innovative Diesel ($1318)
This company’s cost for the Ford 6.0 Powerstroke External Oil Cooler Kit rings in at $1318.00. That’s a pretty hefty price when you compare the overall cost of this part replacement in general.
So, why is it so expensive? This option for the replacement includes a guarantee of one free oil cooler replacement in the future, should your cooler ever fail again after they have first replaced it.
This company’s kit offers several upgrade options, including extra filters, an extreme-duty high pressure pump screen, and a high flow coolant filter (must be purchased as an upgrade to get it at all).
Further, you get filters that work at 100% capacity.
For Diesels – Bostech ($310)
There are, fortunately, much more affordable options when it comes to purchasing your 6.0 Powerstroke oil cooler kit. Bostech makes a kit for models between 2003-2010 that costs around $310.00 normally, but rings in at just $169.95 when on sale.
It includes all the seals and gaskets you need that are domestically made, plus the oil cooler. Once you purchase this kit, you can take your vehicle to be serviced and get the kit installed.
This kit is compatible with over two dozen different Ford models that use the 6.0 Powerstroke engine.
Xtreme Diesel Power ($225)
This oil cooler and gasket kit is made to be compatible with Ford models from 2003-2007 that use the 6.0 Powerstroke engine.
XDP advertises their kit as a good fix to help you avoid engine failure in your Ford truck by replacing the factory part that has long been known to be faulty and a money-eater. It costs a modest $224.99, but note that this doesn’t include a filter.
Compatible with Ford models between 2003-2007, this oil cooler replacement regularly costs a very affordable $143.52, but it can go on sale as low as $128.95. It’s equipped with great features such as FKM seals and leak-free O-rings.
However, note that there is no coolant filter included, and the low cost of this product means you’ll have to shell out some more money for the compatible Mishimoto coolant filter kit.
This replacement kit comes with a lifetime warranty and aims to fix issues like clogging and leaking in your Powerstroke engine’s oil cooler.
Prosource Diesel ($159)
When looking to replace the oil cooler on your Powerstroke engine, you may also consider the Prosource Diesel offer, which rings in at just $159.95.
This oil cooler kit fits dozens of Ford models released between 2003-2010 that use the 6.0 Powerstroke engine. You also get a one-year warranty with this particular purchase.
Cost of a 6.0L Powerstroke Oil Cooler Replacement (Including Installation)
Of course, many people may not feel capable of installing or even have the time to install their oil cooler on their own. If you want to play it safe and get a quality installation, then going to an auto body shop is your best bet.
Below, we’ll break down the average costs of this service (replacement/installation of an engine oil cooler).
On average, the overall cost of a replacement (including parts and labor) is around $565.00, with the highest costs typically being just above $600.00, and the lowest costs being just above $525.00.
Note that these estimates are based on replacement prices for a Ford Super Duty truck (many of which initially used the 6.0L Powerstroke engine when it was released).
And when we break down these costs into parts and repair labor, we find that the replacement parts and cost of labor both consist of about half of your expense:
- Average cost of parts: $230.00
- Average cost of labor: $334.50
Factors That May Affect the Cost of Parts or Labor
It’s important to note that these estimates are fairly accurate, but depending on what region of the US you live in, your costs could fluctuate.
Certain factors, such as the average cost of auto repair service in where you live, taxes, and differences in costs per auto model will affect your cost of replacement.
Further, in some cases, a bad oil cooler comes with related parts issues. Complications in other parts of your car located near the engine may exist, and when you take your vehicle to be serviced, you may have to pay for other services, as well.
Several related auto issues include oil pan gasket replacement, oil cooler filter replacement (or purchase), and more.
What Is the Cost of Replacement Long-Term?
One question that comes to mind when considering the costs of this specific replacement is how often will I have to replace the oil cooler?
One good thing to note about oil coolers in general is that once you have replaced one, they typically last for years to come.
Of course, taking proper care of your engine and using a good oil cooler filter will extend its life. Vehicles that endure frequent and strenuous use (like for towing and driving in extreme conditions) can develop issues like leaks and cracks in the oil cooler or oil leaking into the combustion chamber.
So, the frequency of your oil cooler replacement will depend on how much you use your vehicle and how hard it is working on a regular basis.
Benefits of Replacing Your Engine’s Oil Cooler
Some of the benefits of replacing your oil cooler include improved coolant filtration (when you replace or add a filter) and greater cooler efficiency. Further, one of the key benefits of replacing this component is that it works like an investment.
Replace your faulty oil cooler with a well-made one, and you could save yourself hundreds or thousands of dollars in engine repairs or part replacements down the line by properly caring for the engine you have now.
A good engine oil cooler can actually extend the life of your engine, and then of course there is the obvious advantage of making your engine less susceptible to overheating issues.
Especially for drivers who use their trucks for long distances and heavy hauls in extreme conditions, a good oil cooler is almost essential for the engine’s longevity.
How to Save Money on Your Oil Cooler Replacement
One of the key ways you can save money on your 6.0L Powerstroke oil cooler replacement is by knocking out the hefty costs of installation. Consider yourself keen on parts repairs?
Are you good at following tutorials and feel confident enough to replace the part yourself? If so, you could save yourself around a few hundred dollars on what you would otherwise pay for professional installation fees. Of course, this budget move will vary depending on the cost of services where you live.
Further, it seems that when buying an oil cooler kit for this particular engine, it is overall more affordable to buy a kit that combines both the parts for the oil cooler, as well as the parts for the coolant filter.
Doing so can save you more money (especially on shipping costs) than you would spend if you bought them separately and shipped parts separately.
After the release of the 6.0L Powerstroke engine for Ford truck models in the early 2000s, users quickly found that this part created lots of issues that required frequent repairs.
An engine is one of the most essential and expensive parts of your truck, so if you have this Powerstroke engine, then you need to ensure you have the proper parts.
One essential part most owners have to replace at some point, due to its faulty performance, is the oil cooler.
Buying the kit for this engine and paying for labor will likely cost you upwards of $500 on average, but this cost could be cut significantly if you are capable of buying the kit and installing it yourself.