After replacing head gaskets (Ford OEM) and installing ARP studs, my 6.0 has run very well. However a troubling problem emerged as the miles went on. I would check the degas tank and it would be over full; I drained some coolant out and moved on, then it happened again, I drained more coolant out. I checked that coolant few days later in the drain bucket and there appeared to be fuel separated (floated to the top) in the bucket. A few more days go by and the degas is over full again!

I then completely drained the system and got a very strong smell of fuel. After simply putting tap water back in, knowing it was going to have to be flushed now due to the fuel contamination; the truck was due to go back to the shop for a head re-torque. I got the call a little while ago that an injector cup is leaking and that is the source of the fuel going into the cooling system. The shop is trying to diagnose which head has the leaker so we can replace. I'm planning on having them replace all 4 while they are in there.

1. Has anyone else ever ever experienced anything like this and/or had to replace the injector cups?
2. After fuel contamination, I'm believing I should replace all cooling system hoses, as well as the complete flush, VC-9?
3. Should the cups have been replaced when the heads were off for gaskets/studs?
4. Should I consider replacing the thermostat too?
5. Anything else I should consider (besides selling the truck )

I'd appreciate any insight by our esteemed members.

-Mark

 

You have a cracked head. Cups won't help it. You might try contacting Bullet Proof Diesel and see if they can have it repaired.

 

Tim, thanks I gave them a call and at the present time there is not a fix in for this problem. They are working on a process to solve this however it is not released yet. So I'm going to have to replace the head, darn it! What I will do though is have the shop install hardened seats on this head before this one goes back on, half the battle.

-Mark

 

Update - Does anyone have a set of 07 6.0 heads for sale?
Both of mine are cracked. New are $1375 each locally.

-Mark

 

You can get the heads for $1024 from AutoNation, White Bear Lake, Mn. and that includes the head gasket. You'll have to pay core and shipping 2 ways but if you log into Fordparts.com you can get much better pricing on shipping than going directly to AutoNation.