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

Piston protrusion question

Thread Tools
 
Search this Thread
 
Old Jul 6, 2025 | 03:32 PM
  #1  
vacuumbed's Avatar
vacuumbed
Thread Starter
|
Tuned
15 Year Member
Liked
Loved
Community Favorite
Joined: Apr 2007
Posts: 322
Likes: 42
From: Herriman, UT
Piston protrusion question

Hi everyone,
during my engine build, I installed my crankshaft in one piston just to test the piston protrusion. I know it is supposed to be .034 or less. My pistons are fly cut. Should I be worried if it is over .039 on the area where the piston isn’t fly cut?

The area where it is fly cut doesn’t reach the deck height, so no protrusion.

 
Reply
Old Jul 7, 2025 | 12:52 AM
  #2  
vacuumbed's Avatar
vacuumbed
Thread Starter
|
Tuned
15 Year Member
Liked
Loved
Community Favorite
Joined: Apr 2007
Posts: 322
Likes: 42
From: Herriman, UT
Update. Went from bad to worse after adjusting my measuring instrument.




 
Reply
Old Jul 7, 2025 | 08:16 AM
  #3  
TooManyToys.'s Avatar
TooManyToys.
Hotshot
Photogenic
Photoriffic
Shutterbug
Joined: Dec 2014
Posts: 17,832
Likes: 3,119
From: Jersey Shore
How much was taken off the block deck? Some shops that don't know the engine well take off 0.005" to clean the deck because they are not familiar with this engine's protrusion.

The stock gasket is approximately 0.058" thick, while Fel-Pro provides an additional 0.002".

 
Reply
Old Jul 7, 2025 | 08:47 AM
  #4  
vacuumbed's Avatar
vacuumbed
Thread Starter
|
Tuned
15 Year Member
Liked
Loved
Community Favorite
Joined: Apr 2007
Posts: 322
Likes: 42
From: Herriman, UT
Originally Posted by TooManyToys.
How much was taken off the block deck? Some shops that don't know the engine well take off 0.005" to clean the deck because they are not familiar with this engine's protrusion.

The stock gasket is approximately 0.058" thick, while Fel-Pro provides an additional 0.002".
Hi Jack,
The first machine shop said they removed .008, and I asked a second machine shop to only removed .002 after I noticed a blemish near the fire ring. Hopefully that's all they removed.

It appears that Cometic head gaskets are the way to correct this. They make head gaskets for the 6.0 in four different thicknesses. .053, .062, .067, .071. They only make them to order, and they are 3 weeks out. I need to figure out which thickness I need.

Thank you for your reply.
 
Reply
Old Jul 10, 2025 | 03:26 PM
  #5  
vacuumbed's Avatar
vacuumbed
Thread Starter
|
Tuned
15 Year Member
Liked
Loved
Community Favorite
Joined: Apr 2007
Posts: 322
Likes: 42
From: Herriman, UT
Update and conclusion.

I double checked my measurements and if I rock the piston in the cylinder with my fingers, the protrusion is a bit higher. .048 for the passenger side and.045 for the driver side. I’m going to try the head gaskets made by Cometic. They made them in thicker options, .062, .067, and .071. I think the.071 is the best one for my situation. I ordered two of them.

Just got the freeze plugs in.



 
Reply
Old Jul 10, 2025 | 04:23 PM
  #6  
Hartwig's Avatar
Hartwig
Cargo Master
Photogenic
Shutterbug
Loved
Top Answer: 1
Joined: Oct 2018
Posts: 2,811
Likes: 1,909
From: unfortunately Germany
Club FTE Gold Member
What advantage do you expect from these pistons? Why not the original piston type?
 
Reply
Old Jul 11, 2025 | 01:32 PM
  #7  
vacuumbed's Avatar
vacuumbed
Thread Starter
|
Tuned
15 Year Member
Liked
Loved
Community Favorite
Joined: Apr 2007
Posts: 322
Likes: 42
From: Herriman, UT
Originally Posted by Hartwig
What advantage do you expect from these pistons? Why not the original piston type?
They are the original type, made by Mahle. I paid Dynamic Diesel, whom I bought them from to do .010 compression reduction, the fly cuts and the coating. I think it was all necessary, except for the coding. Hopefully everything works out well.
 
Reply
Old Jul 12, 2025 | 01:13 PM
  #8  
Baylinerchuck's Avatar
Baylinerchuck
Cargo Master
Photoriffic
Community Builder
Liked
Loved
Joined: Dec 2021
Posts: 2,391
Likes: 996
From: Chambersburg, PA
I’d love to see that engine fully assembled…..part look so good in that paint. Hope all works out good for you.
 
Reply
FTE Stories

Ford Trucks for Ford Truck Enthusiasts

story-0

Top 10 Fords at 2026 Carlisle Ford Nationals

 Joe Kucinski
story-1

3 Best / 3 Worst Parts of Modern Ford Ownership

 Brett Foote
story-2

10 Amazing Upgrades That Solve Common Ford Truck Owner Headaches

 Pouria Savadkouei
story-3

Every 2026 Ford Engine Explained

 Brett Foote
story-4

10 Ugly Ford Trucks That We Still Kinda Love

 Joe Kucinski
story-5

10 Things Every Truck Owner NEEDS (2026 Edition)

 Michael S. Palmer
story-6

Rezvani's Latest Post-Apocalyptic Monster Is a Ford F-150 Raptor Underneath

 Verdad Gallardo
story-7

Top 10 Most Expensive Ford Trucks Ever Sold on Bring a Trailer

 Joe Kucinski
story-8

2027 Ford Super Duty Buyer's Guide (Every Model, Engine, & Package)

 Brett Foote
story-9

Top 10 Ford Truck Tragedies

 Joe Kucinski
Old Jul 12, 2025 | 02:18 PM
  #9  
vacuumbed's Avatar
vacuumbed
Thread Starter
|
Tuned
15 Year Member
Liked
Loved
Community Favorite
Joined: Apr 2007
Posts: 322
Likes: 42
From: Herriman, UT
Originally Posted by Baylinerchuck
I’d love to see that engine fully assembled…..part look so good in that paint. Hope all works out good for you.
Thank you Chuck, I just lowered the crankshaft in to the block. It was heavy with just me.

 
Reply
Related Topics
Thread
Thread Starter
Forum
Replies
Last Post
ChrisMelton78
1999 - 2003 7.3L Power Stroke Diesel
26
Aug 31, 2019 09:38 AM
Romel77
Pre-Power Stroke Diesel (7.3L IDI & 6.9L)
23
Feb 11, 2016 06:13 AM
rnelson664
Performance & General Engine Building
5
Oct 21, 2007 10:59 AM
TMI
335 Series- 5.8/351M, 6.6/400, 351 Cleveland
3
Dec 23, 2004 11:50 PM
danimal
Ford Inline Six, 200, 250, 4.9L / 300
1
Mar 11, 2003 09:23 PM




All times are GMT -5. The time now is 09:42 AM.

story-0
Top 10 Fords at 2026 Carlisle Ford Nationals

Slideshow: Top 10 Fords at 2026 Ford Nationals

By Joe Kucinski | 2026-06-09 11:10:08


VIEW MORE
story-1
3 Best / 3 Worst Parts of Modern Ford Ownership

Based on years of owning multiple modern Ford products.

By Brett Foote | 2026-06-09 10:53:36


VIEW MORE
story-2
10 Amazing Upgrades That Solve Common Ford Truck Owner Headaches

SPONSORED: From muddy boots to rain-soaked cargo, these upgrades address some of the most common frustrations Ford truck owners face every day.

By Pouria Savadkouei | 2026-06-08 18:50:34


VIEW MORE
story-3
Every 2026 Ford Engine Explained

Here's everything you need to know about every Ford engine available for the 2026 model year.

By Brett Foote | 2026-06-05 12:58:01


VIEW MORE
story-4
10 Ugly Ford Trucks That We Still Kinda Love

Slideshow: 10 ugly Ford trucks that we still kinda love.

By Joe Kucinski | 2026-06-03 09:51:16


VIEW MORE
story-5
10 Things Every Truck Owner NEEDS (2026 Edition)

Slideshow: the best gifts for dads & grads

By Michael S. Palmer | 2026-06-03 15:43:58


VIEW MORE
story-6
Rezvani's Latest Post-Apocalyptic Monster Is a Ford F-150 Raptor Underneath

Slideshow: Called the Fortress, the 850-horsepower pickup combines Raptor underpinnings with military-inspired features, survival equipment, and a starting price of $285,000.

By Verdad Gallardo | 2026-06-03 11:38:36


VIEW MORE
story-7
Top 10 Most Expensive Ford Trucks Ever Sold on Bring a Trailer

Slideshow: 10 most expensive Ford trucks ever sold on Bring a Trailer.

By Joe Kucinski | 2026-05-27 16:24:34


VIEW MORE
story-8
2027 Ford Super Duty Buyer's Guide (Every Model, Engine, & Package)

Here's everything that has changed for the latest model year.

By Brett Foote | 2026-05-27 16:17:28


VIEW MORE
story-9
Top 10 Ford Truck Tragedies

Slideshow: Top 10 Ford truck tragedies.

By Joe Kucinski | 2026-05-18 19:34:33


VIEW MORE