Just a followup....finished the job, it wasn't the head gaskets, it was a cracked head. Cracked between the valves. The job wasn't as bad as I had thought it would be, just time consuming, mostly because I took my time. Some tips...
- Use OEM gaskets. Nothing else. Felpro head gaskets will not last. I know from experience.
- the exhaust manifold nuts were pretty stuck, so I removed the heads with the manifolds attached. Way easier work on getting them off when the heads are on a workbench.
- I should have acquired new manifold studs/nuts before starting. If they are in bad shape, you'll want to replace them. I re-installed the heads first and then the exhaust manifolds. You don't want to snap any of these off when torquing them back on after the heads have been torqued! None of the local auto stores had any, and the local Ford dealerships only had a couple each. So that delayed things.
- Use good quality tools. I had a cheap thread chaser, and didn't like it, so I sprung for a ARP M12 x 1.75 thread chaser. It was expensive ($70 with shipping and handling), but WELL worth it. It fit and worked perfectly.
- Look at the job in stages. Seeing just the block in the truck and parts all over the place was a bit overwhelming. Much easier to look at the work in stages - cleaning the block face, done. Getting the heads checked, done. Install and torque heads, done, etc.
- Watch out towards the end of the job. I didn't spend the time I should have on one of the valve covers because I wanted to finish, and ended up with an oil leak. Had to tear into it again to fix that. Patience at the end is just as important as at the beginning!
- No washers on the headbolts, cleaned the headbolt holes real well and chased them. Then used the advice above to lightly oil (30w) the headbolt threads and underside of the top. They torqued in smooth, no squeaking or sudden movements. Oh, and marking the bolts with a sharpie is good advice too for the final degree turn. It really helps give a visual to make sure you didn't forget one and that you got it right.
Things turned out well, she started right up, stumbled just a little, then ran smooth. No CE light, no strange sounds, and no more steam out the tailpipe
