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6.0L Power Stroke Diesel 2003 - 2007 F250, F350 pickup and F350+ Cab Chassis, 2003 - 2005 Excursion and 2003 - 2009 van

First time head swap on a 6.0L - It begins....

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Old Jul 1, 2024 | 11:06 AM
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I did mine in five steps, with a minimum wait time of 30 minutes between the fourth and fifth sequences.

I did that to have a more even step up in clamping force. It's well-known in engineering that there is a period of relaxation once a fastener is tightened down. So, if you do the last step right after the last one, you may not end up with a full clamping load. You can use the same principle by doing a final torque check 30+ minutes after the final torque. This is especially true when dealing with a gasket between the two clamped objects.

I also used a permanent marker to identify where I ended up so that it's easy to tell if the bolt or stud ever backs off.





 
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Old Jul 1, 2024 | 12:20 PM
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Well I didn't want to wait, so I did 65, 135, and 210. I'll go back over them to double check.
 
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Old Jul 1, 2024 | 12:25 PM
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Most people do that. I took a different approach. It's also not a bad idea to plan for a recheck after some heat cycles. However, any fastening engineer should take that relaxation into account during the final step and consider it will settle where they want it to (clamp load).

The best way to do a post-initial tightening check is to back off 10 degrees or so and re-torque to the spec. Just going to the 210 lb-ft value does not consider the break-a-way high static friction you have to overcome unless the relaxation is so significant that the static friction is under the target.

 
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Old Jul 2, 2024 | 07:44 AM
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Got the right side buttoned-up.








 
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Old Jul 2, 2024 | 08:14 AM
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Plenty of room with left side of engine jacked-up about an inch.

 
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Old Jul 2, 2024 | 02:25 PM
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Originally Posted by Fuzzpuss
You get used to the heat when you have no choice. It's an annual acclimation process for me. I think that process is finally complete for this year.
Amen 🙏?

Working outside all over Texas, it takes a hot minute (pun intended) to get used to the heat. Once you do, the trick is to stay hydrated and you'll survive. If you had issues sleeping, you sleep REALLY well after a hot day out in the sun.
 
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Old Jul 2, 2024 | 03:30 PM
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Originally Posted by Toreador_Diesel
If you had issues sleeping, you sleep REALLY well after a hot day out in the sun.
Unless, of course, you over do it, and end up with a mild case of heat stroke, in which case you go to bed with a pounding headache. It has happened more times than I care to admit.
 
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Old Jul 2, 2024 | 03:42 PM
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Thinking a few days ahead, what are the protocols for pre and post engine start-up?

1. Pumping fresh oil into the port at the front of the oil cooler?
2. Put used oil filter back in (stored in new ziplock freezer bag) and do an oil change in a few hundred miles?
3. Coolant flush and oil cooler back flush in a few hundred miles?

 
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Old Jul 2, 2024 | 04:58 PM
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Originally Posted by Fuzzpuss
Unless, of course, you over do it, and end up with a mild case of heat stroke, in which case you go to bed with a pounding headache. It has happened more times than I care to admit.
Did that last month, wasn't fun but managed to save myself a trip to the hospital. I'll tell you a story about Las Vegas next time I see you.
 
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Old Jul 2, 2024 | 06:08 PM
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Is it smart to chase the head bolt threads in the block or are they a particular class of thread?

Asking because I blew them out really well, buts some of the studs didn't want to thread as deeply as others on the right side.
 
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Old Jul 2, 2024 | 06:11 PM
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Chris, I chased the internal threads by cutting a groove down one of the old head bolts. I'll try to find a photo.
 
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Old Jul 2, 2024 | 06:12 PM
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You could grind down the tip to the first thread, too.
 
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Old Jul 3, 2024 | 09:41 PM
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The hard part is done









 
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Old Jul 4, 2024 | 06:23 AM
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Both of those surfaces looked great, Chris. I'm curious: How many hours did it take you to lap them while doing that in-cab?
 
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Old Jul 4, 2024 | 07:57 AM
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The first side (right) took about 7 hours. The left side took about 6 hours.

For my own piece of mind, I have to pull the left head back off to make sure I got all of the foam pieces out of the water jackets. I'm 95% sure I did, but I was rushing, I was aggravated that I had to fish out a few of them, AND I gashed my head on the corner of the degas bottle mount while I was fishing one out of the back cylinder. So I was a little distracted.

I have only tightened the inner row bolts hand-tight. Hoping I can reuse the head gasket.
 
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