Headgaskets on 2005, How To? - Ford Powerstroke Diesel Forum
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Old 11-06-2007, 12:18 PM
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Headgaskets on 2005, How To?

Hey guys,

Well, after spending the summer towing cars all over the country, I think the headbolts have finally stretched their all. I keep losing coolant through the reservior and am well over the 36,000 mile warranty mark(47,700). The last few times I have towed, I noticed the coolant temp gauge spiking while climbing some hills(60 degree ambient temps, hardly high temps). I plan on doing the gaskets and studs, repair any damage, and bypass the EGR cooler assembly.

I used to have the online shop manual downloaded but I think my wife cleaned it off the computer. I checked through my old threads where a previous link was posted but did not find an installation manual where there used to be one. Can someone help me out and post the following?

Headgasket how-to? Mainly pulling the cab and order of operations so I don't cost myself more $.

EGR blockoff tips? I'm a fabricator by trade so I can modify what needs to be modified.

Any other longevity tips?

I have a two post lift so I will be pulling the cab for ease of workspace. Also, I have set aside a week with no vehicle.

Thanks in advance!
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Old 11-06-2007, 12:46 PM
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Your truck should have a 5 year 100k mile powertrain warranty?
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Old 11-06-2007, 02:13 PM
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Nope, 3 year, 36000 mile. 5 year/100k on the rest of the truck. I got jacked.

Any links to an online cab removal/HG manual yet?
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Old 11-06-2007, 02:15 PM
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You might want check to be sure but the normal ford warrenty is 5years/100 thousand on the engine. 3/36 on everything else
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Old 11-06-2007, 02:31 PM
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Well what do you know...I just dug my owners manual out of the glovebox and the $100.00 deductible that begins at 36,000 miles, must have confused me as to when the warranty ends. 5 year, 100k mile warranty on the 6.0 so I guess thats good.

Either way, the truck is well-known in town to have been "raced" so the warranty repair will more than likely be turned down.

I have not towed with the SCT in the truck since early this year, but I do daily drive it that way. Obviously they will know and I frankly don't want to skiver around the fact. The last time I was there, the Tech made a note along these lines, "suspects programmer was used." I did pull the SCT beforehand, and will probably do it again just so the truck is as factory-like as possible.

Incase my dealer isn't up to performing the repairs under warranty, I would still like directions to the info if at all possible.

Thanks!
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Old 11-06-2007, 02:35 PM
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try another dealer, sweet talk the tech and see if he'll put the studs in for you.
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Old 11-06-2007, 03:17 PM
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I think I might. Sucks that the other dealer is 50+ miles away. That'll cost me $30.00 just to drive their. Doh!

I'm still searching for instructions...yes, actually searching
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Old 11-06-2007, 03:18 PM
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Buddy, take it to another dealer. Even if that other dealer suspects something fishy I bet they will perform the warranty work. Times are really tough for Michigan dealers right now and they will not turn away the work. Even lower commisioned warranty work. If by some chance they dig in their heels tell them you're going to take it to an independent shop. Trust me, they don't want to lose the business.
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Old 11-06-2007, 04:02 PM
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Dealership is the best way and you can get that EGR cooler replaced at the same time. Oh, and since you have the 05, get a sneaky pipe and block off your EGR. LINK
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Old 11-06-2007, 04:39 PM
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Yeah, if you have to pay for that repair out of pocket, you're gonna be out at least a few grand. Why don't you drive it down to the N.C meet and go visit the local dealer there. The most you'll be out is the fuel and airfare back and fourth.
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