I think if you checked the heads you will find them warped.

 

Not interested in the heads. Just whether glow plugs and piston damage would be visible well doing head gasket job.

 

well you can see the tops of the pistons clear as day when doing heads .. specially if it were done "cab off" however I couldn't find (or did u) post pics of the piston damage?

 

How many miles on engine since last HG repair?

 

I think he also would like to know if:
1) the overly-long glow plugs would be visible and obvious during head gasket job?
2) the glow plugs would typically be (or necessarily) removed during head gasket job?

I have no idea how obvious these wrong parts would be as I have never done head gaskets on a 6.0, or any other diesel. Anyone here done one that can help him out?

I'm sure that at this point the OP has been educated on a couple of items that point to responsibility on others than Ford and probably now accepts that Ford may or may not have any responsibility at all, but needs information to determine this conclusively. He has poured quite a bit of money into this job so far and just wants to know whether to accept or dispute this.

On a side note to the OP, I think your performance tuners certainly at least contributed to the problems, if not the culprit. Personally, I keep my truck stock for this reason. When people choose to bump up performance they accept the possible consequences of engine failure as well. But you would think the bent glow plugs would have been noticed during the repairs eh??? And the question still remains, could this have anything to do with these failures? Suspicious to me...

 

You hit the nail on the head!

 

Of course. I would even say "impossible to miss" you have to clean/prep the block mating surfaces (deck) before re-assembly. I would also assume new heads would have valves and springs installed but injectors, glowplugs, and misc brackets would come off the old heads.

 

Yes glowplugs injectors and top of piston are all clearly visible when pulling the head and should be inspected regardless before putting them back in the motor it can be done without taking the gp's and injectors out but is much easier to just take them out. If you do not take them out they can be damaged by setting the head down on the table or floor or when removing the head and bumping the bottom on the motor or whatever because the glowplugs and injectors stick out the bottom of the head

 

The 2003 6.0 engine takes the longer glow plug, when they updated the bowl design of the piston in 2004 they required a 1.2mm or .047 shorter glow plug. The only way to have glow plug/piston contact in a 2003 6.0 engine would be from using pistons from the updated design in the engine. Was this engine built around the transition time? Is it possible the pistons in your engine are of the updated design? You say the ICP is back behind the turbo. If you have a true early 6.0 either glow plug would never make contact with the piston

 

I am not going to second guess what He wants

I kept it short and to the point

 

Hope it all gets settled in the end for ya.
It seems there are a few that get wound up and like to bash.
Rained on their blue oval parade.

After seeing my engine apart I can't see why the problems keep coming with some of these engines. The engine is very small IMO. I just could not believe how well put together it is for such a small engine. Over thought even.
Amazes me how just a few small loose ends can bring things to a stop.
Bolts that can't even handle a stock truck. My gaskets were blown between cylinders ,and the truck never has had any type of a tuner on it.

 

Yea, it's a tricky beast the ole 6'0! The new motor isn't a FORD OEM it's got ARP's, upgraded piston, cam and some other goodies. I'd list them if I had any idea what it means lol But my installer said it was a great replacement and can easily handle the setup I have. He said stay away from the reman. some have less than OEM piston and other internals.

It will be nice to drive the truck and not have to worry about "what's gonna break next"! Well at least for a few years hopefully! lol

 

Alright Gentlemen, back to the subject.

 

Another thing I would like to know is if the OP bought this truck new? Another issue is when you sell this truck, if it is not clearly understood that the pistons in the engine are of the updated design, the new owner will make the same mistake. If a 2003 motor which takes a long plug and is rebuilt using updated pistons, now has to use short plugs.

 

Good question