Felpro Head Gasket Failure

[dwadholm]

Any ideas what would cause this gasket failure?

A little background? Engine is a 2006 3.0 from a Taurus. I swapped everything over including the appropriate truck head gaskets. Torqued to specifications with new bolts. After 3K miles I noticed cloudy coolant. After 10K the truck started sputtering under load and eventually wouldn't start.

 

[sheep herder]

Warped head?

 

[Dirtman]

Block or head was not prepped properly or straight enough (warped).

That head gasket looks wrongly aligned with the coolant passages and at 3,000 miles the amount of rust is quite disturbing.

 

[RonD]

Yes, for sure have the heads tested and surface at a machine shop before reinstalling