9200 miles and putting another set of head on!

[Sno-Mow]

So, 9200 miles ago I put brand new OE heads on from Ford (old ones were cracked). While doing the project I put in A1 Technologies studs, OE head gaskets, injector o-rings, EGR cooler delete, oil cooler, FPR blue spring upgrade, banjo bolts, stand pipes, y-pipe (mine was cracked), intake and exhaust manifold gaskets, IPR, IPC, Turbo drain pipe update, and thermostat. HPOP was replaced about 15000 miles ago.

I was having black smoke and lack of power so I pulled the compressor side of the turbo to find oil EVERYWHERE and the oil level low. Brought the turbo in and it was toast and had it rebuilt.

Back on the road, still black smoke. Found 2 injector o-rings leaking on the passenger side and decided to pull the drivers side...this is when the fun began! To my surprise I found 2 injector cups with coolant in them. I parked it til I had time to check it out further.

Today I pulled all 8 injectors and pressurized the coolant degas to find 2 cups leaking on the drivers side, and 2 leaking on the passenger side. I pulled the heads off to find BOTH head gaskets were blown too! Ford is replacing BOTH heads (parts only) under warranty and I'm doing the work.

So my question is...WHY did my heads last this long? I do a lot of hauling during the summer (9 out of 10 days I'm pulling 6k pounds), and plow snow with the monster. I have had a turbo code off and on (po132b) but went away with the turbo rebuild (granted it was only 200 miles ago). I scan the truck constantly to make sure there's no codes and repair anything as it comes up. My cylinders look great with the honing swirls still and pistons look great.

Stats on the truck:
2003
281k miles
4" straight pipe/3.5'' downpipe
S&B Cold Air Intake
Boost and EGT Gauges
Stock Programming

[Kyle K]

If i were buying a new set of heads i would still take them from the box straight to a machine shop to check them out.

[PSDMikeB]

My machine shop indicated that straight from Ford the heads aren't flat enough, and their surface finish is not smooth enough to get a good seal. Your problem (coolant in cup) sounds more like a crack issue and possibly flawed casting?

MikeB

[Sno-Mow]

I thought about bringing the heads the first time to a machine shop but a buddy of mine who's a mechanic by trade said to forget that.

Guess when I get the new heads I'll bring them in, what the hell its cheap insurance.

The nice part is that I caught it early and Ford is giving me replacement heads under warranty

[Sno-Mow]

So I just spoke to the stealership and they found it odd that BOTH heads are leaking and FORD is arguing about it AFTER the stealership said they would replace the heads.

I found it interesting that the heads which were "the updated" heads that I bought in 9/2012 are no longer available and have been replaced by another "updated" head

I'm guessing I maybe getting an attorney involved in this whole matter. Its almost like they think I ENJOY pulling their junk apart.

[Sno-Mow]

Quick update: Took the glow plugs out of the junk heads today and found to my suprise...Crusted coolant in 3 holes of the drivers side and oil in all 4 holes in the passenger side head.

Any thoughts? My guess is that for sure the heads are screwed and will be bringing them to the machine shop mainly because I'm curious to find out exactly what is wrong! Hell, if it wouldn't cost me another $1200 I would section it apart to see inside the passages.

Keep in mind these heads have about 9200 miles on them and were bought BRAND NEW from Ford.

[Sno-Mow]

So, both heads were cracked. The replacements went from box to machine shop. Both were warped .006 & .0055!

I found a machine shop that machines this garbage and rebuild them because mine won't.

I'll be putting it back together today.

[ZMANN]

What a disaster

From what I have read ford only sells reman Heads and that may be wh the part number changed ?
and their tolerance for good is less than Ideal

have fun !!