Gentlemen

Here is the issue, and keep an open mind. My 2004 6.0 is showing signs that the DEGAS bottle has begun to spit up a very small amount of coolant onto the outside of the bottle from the cap. Usually no more than a couple to a dozen drops when it does. It does this at random times and not under a load. I monitor the engine very closely when I drive and the EOT/ECT spread is never more than 8 degrees apart. I have read about how guys always jump to HEAD GASKETS for the 6.0 but my gut tells me its something else and heres why.
-BPD EGR
-BPD Oil Cooler
-Blue Spring Kit
-5" MPRP turbo back exhaust
-Prestone Command Cat-1 coolant (ELC)
-All injectors have been replaced within last 50k
-Coolant filtration system
-Block Heater installed
-Fuel Filters within 5k
-Shell Rotella T-6 for all oil changes

Now, I know that nothing there guarantees that the head gaskets will be fine, but it is hard for me to believe; with how well this truck is kept and how well it runs that there is really a HG issue,especially considering how my exhaust is clear and there is no white smoke no matter how much i get on the throttle and boost pressure is well within parameters, as a matter of fact all parameters are right where they should be (EGT/EOT/ECT/FICM/BOOST/ ExBP/ Batt Voltage/ ICP/IRP). If it is a HG issue than so be it, I will just have to pay the money to get it fixed, but I am looking to your guys experience for what you know or have seen before you go tearing the engine apart. Anything you have seen that was mistaken for a HG issue that was not, but a smaller fix? ANYTHING????

Thank you for all the help guys

 

Maybe time for a new cap? Also check the mating surface for cracks. You're sure it's the cap, as I had a polecat bite the coolant filter hose and cause something similar, took a while to find because the holes are needle small.

 

First thing to check, the coolant level. The "low" like molded on the bottle is what you should be using as a "max cold" line. Does your bottle have the updated sticker showing this?

If coolant level is good, a pressure test with a gauge plumbed into the coolant is a good next step.

 

I had to google this one... For all the other Americans here who have no idea what a polecat is, it's what we call a ferret.

 

 

That's a new one for me. Over here we put tame ferrets down rabbit holes to flush the rabbits into nets. What do you call those?

 

 

I have no idea, we use water and shotguns to get rabbits out of holes over here!

 

 

That's a good comparison of the two. Ferrets are also good for flushing out rats, just listen to the squealing!
Polecats were a real pain back in Germany. Apart from the hose they cut a spark plug cable so we had to put hard plastic tubing over them all, and they thought the truck motor was great for storing food, dead mice etc. the batteries were perfect tables apparently...

 

Reading what you have done already it is easy to assume a leaking headgasket. But it needs to be verified. You must T in a pressure gauge on the small hose going to the degas bottle. Take it for a hard drive. Once hot, 186°f+, open the cap slowly to release pressure. Then tighten it back down and take it for another hard drive. If you have a trailer to tow to make the truck work, it would be even better. On this 2nd drive from a rolling start floor it for as long as you can safely. Watch the gauge. If you see the gauge climb rapidly, usually hitting the 15-20 mark, then you have combustion gasses entering the water jacket of the engine. The cause is usually head gasket.
Also Normal pressure build up in these engines from a cold start to operating temp due to expansion is 9 psi.

 

I always thought a polecat was a liberal.

 

As Euroman posted, make sure the cap surface is smooth and level. Some people have had to sand on theirs to get it right,

Good advice on installing a pressure gauge!

BTW - I don't see it mentioned ....... Are you tuned?