How to Upgrade and Replace Oil Cooler On 6.0 Powerstroke

If you go through customer complaints about 6.0 Powerstroke engines, you will see lots of them are on faulty oil coolers.

Whether yours has gone old or somehow became bad, you must know how to upgrade and replace oil cooler on 6.0 Powerstroke diesel engine.

In this article, I have not only included the steps to do it but also given the necessary information for your convenience. Let’s get started.

How Do I Know My Oil Cooler On 6.0 Powerstroke Is Bad?

The main purpose of an engine oil cooler is to remove the excess heat from the oil eliminating all sorts of overheating-related issues.

But the cooler can go bad for various reasons. Before knowing the causes, you have to know how to detect such an issue.

Because an undetected bad oil cooler can cause serious damages to the engine. Let’s see some symptoms to detect an oil cooler not working smoothly.

1. Leaking Oil from the Cooler

The oil cooler adapter is the link between the oil lines and the cooler. There is another adapter that transfers the cooled oil back to the system.

Now, there is a gasket or rubber O-ring within those adapters which can fail at any time. Thus, oil gets out of the cooler and you can see dripping oil below the truck.

Depending on the severity of the leak, you will notice the amount of oil outside the truck’s engine. Immediately after noticing this, you have to take the truck to your mechanic for a thorough check and solve the issue.

2. Leaking Engine Coolant

Besides oil, engine coolant can also be leaked from the cooler. The loss of coolant overheats the engine which you may notice in engine diagnosis.

Also, take a look at the ground underneath your Ford Truck. It is highly likely that you would notice coolants dripping on the ground.

3. Oil in the Cooling System

Due to cracks or other reasons, the oil may end up in the cooling system. Now, remember that the problem only occurs when the engine is running.

As oil pressure becomes greater than the pressure of the cooling system, it causes a lack of lubrication and some serious damages.

4. Oil Coolant Mix-up

Another possible situation by which you can detect your truck’s oil cooler is not working properly is by seeing coolant and oil mix-ups in the oil pan.

Those are some of the signs and symptoms of a failing oil cooler that can tell you that a replacement is necessary.

When Should You Replace?

After knowing how to detect this bad part, another question logically comes into our minds. It is about the longevity of the oil cooler.

So, How Long Does an Oil Cooler Last?

Having an oil cooler is very important because it keeps the engine safe from overheating. 

If you are taking good care of the truck and maintain the oil cooler, you should get a lifespan the same as the truck.

It is possible by acting upon detecting a problem without any delay. However, a 6.0 Powerstroke oil cooler performs poorly for a few years which is normal.

So, the answer is hard because there is no durability mark on this part. Nonetheless, I have already given you the answer to the question of when to replace.

Read the previous section on ways to detect a bad oil cooler in a 6.0 Powerstroke engine, and you can understand when to install a new one.

Here, let me tell you the moments of replacing the old oil cooler in a few points below.

  • Replace the oil cooler when the engine keeps losing power
  • Replace the oil cooler when you notice misfires due to oil in the cylinders
  • Replace the oil cooler when the engine temperature is increased dramatically
  • Replace the oil cooler when you see increased exhaust fumes than usual

How Much Does It Cost to Replace?

First of all, the price of a new oil cooler varies depending on the brand. It can be somewhere between 100 and 350 dollars.

If you are looking for an OEM part, it will cost you more than $300. Check out this OEM Updated Engine Oil Cooler from Ford on Amazon.

Now, consider the labor cost of replacing a part which one can easily avoid by doing it themselves.

Assuming that your mechanic is charging somewhat between 150 and 200 dollars to do the job, you have to spend approximately $500 to replace the oil cooler on 6.0 Powerstroke.

How Hard It Is Replace Oil Cooler On 6.0 Powerstroke?

I don’t have to answer this question because you will know it yourself after reading the next part.

I have explained the steps to replace the oil cooler in the 6.0 Powerstroke engine and included a video at the end.

Indeed, it requires some work and commitment but you can do the job using some basic tools. All one requires are a 9 or 10mm deep socket, a Torx bit set, and an inch-pound torque wrench.

How to Upgrade and Replace?

From the last point, you have known the tools required for this replacement job and understood that anyone can do it at their home.

However, you must keep in mind that the task requires a few hours. So, those who don’t have the time or patience should hire a mechanic. Let’s see the steps below.

  • Firstly, locate the bolts of the intake mount and loosen them. Removing the intake is not that hard.
  • Secondly, you may notice some dust in between the oil cooler housing and the front cover in case the engine has not been serviced recently. If that is the case, it will be better to clean any kind of dust or dirt.
  • Then, take a rag and place it inside the engine so that any kind of oil dripping doesn’t make the garage floor or other truck parts dirty.
  • Next, you have to remove the cooler’s top part while carefully loosening the bolts and screws. Watch the video I have linked below, and you will know how to do it.
  • After that, take out the oil cooler slowly because it is soaked with oil. Give it a minute or two to drain most of the oil.
  • It is time to separate the housing of the oil cooler in the 6.0 Powerstroke engine.
  • Finally, put the O-rings on the newly purchased cooler, place it in the housing, and repeat all of the steps in a reverse manner.


I think that I have covered almost everything on how to upgrade and replace oil cooler on 6.0 Powerstroke diesel engine. If you still have any questions, you can mail me anytime, and I will try to answer as soon as possible.

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