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Ford 6.0L Head Fix: Injector Bore Crack Repair Made Easy

The Ford 6.0L engine was made for Ford by International, and, like the 7.3L, it has had its share of problems. In general, both of these engines have provided good service. One issue commonly seen on the 6.0 is a condition where the heads develop micro-size cracks inside the injector bores of the heads. These cracks are small, but they can lead to big issues.

1. The first step of the diagnosis it is to remove the valve covers on both heads. Then drain the coolant. You will need to remove the coolant passage plugs in the heads to get the level low enough to do the leak test.
1. The first step of the diagnosis it is to remove the valve covers on both heads. Then drain the coolant. You will need to remove the coolant passage plugs in the heads to get the level low enough to do the leak test.

Since the fuel system in modern diesels runs at ultra-high pressures, even a tiny crack can create a path for trouble. The most common result of cracks in the 6.0L injector bores inside the head is fuel finding its way into the cooling system. Once this happens, you can get frothing of the coolant and then the rubber components in the cooling system will begin to deteriorate.

In the past, the only solution was to replace the offending head. This was a costly proposition, until now. Bullet Proof Diesel introduced a unique tool to fix your 6.0’s cracked head woes—their 6.0L Cylinder Head Repair Kit.

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Using the latest technology available, the Bullet Proof Diesel cylinder head repair tool kit simply seals the small cracks in the injector bores. This may seem like snake oil to some, but the truth is the space-age crack bonding cement has proven reliable, durable and long lasting. In truth, it’s more common for a different injector bore to develop a crack, than to have one repaired properly with their kit to leak again.

2. The leak test is best done one head at a time. First, the fuel rails are removed from the passenger-side head to access the injectors.
2. The leak test is best done one head at a time. First, the fuel rails are removed from the passenger-side head to access the injectors.
3. Each injector is removed and set aside. It’s a good idea to keep the injectors in order, so you can inspect each one and take note of any other issue you have on a cylinder-by-cylinder basis.
3. Each injector is removed and set aside. It’s a good idea to keep the injectors in order, so you can inspect each one and take note of any other issue you have on a cylinder-by-cylinder basis.
4. With the injectors out, you need to carefully clean and then dry each injector bore. In order to do the leak test, the cooling system needs to be closed up, so replace the drain plugs in the head.
4. With the injectors out, you need to carefully clean and then dry each injector bore. In order to do the leak test, the cooling system needs to be closed up, so replace the drain plugs in the head.
5. Install the rubber stoppers in each injector bore in the one head you’re working on. The bore is then filled with WD-40. Believe it or not, this makes a great bubble test solution and unlike soapy water, it won’t contaminate your fuel system.
5. Install the rubber stoppers in each injector bore in the one head you’re working on. The bore is then filled with WD-40. Believe it or not, this makes a great bubble test solution and unlike soapy water, it won’t contaminate your fuel system.

We stopped in at Domestic Diesel in Chino, California, to see how this new head repair kit from Domestic Diesel works. Owner John Ferguson walked us through the process. He reminds us that not all 6.0L head issues can be repaired using this kit. However, for those that it can address, the cost of the repair is much lower than a new set of heads.

If your Ford 6.0L is showing signs of fuel in the coolant, the Bullet Proof Diesel 6.0L Cylinder Head Repair Kit could be the solution. It’s simple enough to use that a competent weekend mechanic, familiar with the Ford diesel, can use it. Remember, while this kit might fix your problem, if your heads are beyond repair, they will have to come off. This is a huge task and best left to a shop, unless you really love to get up to your elbows inside diesel engines.

Follow along and we’ll show you the highlights of fixing injector bore cracks on a Ford 6.0L. DW

6. Pressurize the cooling system to no more that 20 psi and then check the injector bores for bubbles. Bubbles means a crack in that injector bore. None and that cylinder is fine.
6. Pressurize the cooling system to no more that 20 psi and then check the injector bores for bubbles. Bubbles means a crack in that injector bore. None and that cylinder is fine.
7. This is what a bad injector bore looks like with the test. Bubbles means a crack in that injector bore. None and that cylinder is fine.
7. This is what a bad injector bore looks like with the test. Bubbles means a crack in that injector bore. None and that cylinder is fine.
8. Once the head has been checked and any bad injector bore noted, you can begin the repair. First, the injector bores that need to be fixed must be completely cleaned and dried. Forget to do this and the crack fix repair will fail.
8. Once the head has been checked and any bad injector bore noted, you can begin the repair. First, the injector bores that need to be fixed must be completely cleaned and dried. Forget to do this and the crack fix repair will fail.
9. This is the first of two major components of the Bullet Proof injector bore repair kit for the 6.0L Power Stroke engine. This tool fits into the injector bore and is indexed to always face the same direction in relationship to the head/bore alignment. This ensures that the crack sealant is always targeted at the proper location. Apparently, the crack in the bore is always in the same location. We speculate that this must be due to an inherent flaw in the design of the head.
9. This is the first of two major components of the Bullet Proof injector bore repair kit for the 6.0L Power Stroke engine. This tool fits into the injector bore and is indexed to always face the same direction in relationship to the head/bore alignment. This ensures that the crack sealant is always targeted at the proper location. Apparently, the crack in the bore is always in the same location. We speculate that this must be due to an inherent flaw in the design of the head.
10. It’s important to lube the bore repair tool before each use. Follow the instructions to the letter to ensure a proper repair.
10. It’s important to lube the bore repair tool before each use. Follow the instructions to the letter to ensure a proper repair.
11. After installing a gumball-sized plug of paper inside the injector bore, per the instructions, the tool in inserted into the injector bore.
11. After installing a gumball-sized plug of paper inside the injector bore, per the instructions, the tool in inserted into the injector bore.
12. The EOM injector clamp is used to secure the bore repair tool in place.
12. The EOM injector clamp is used to secure the bore repair tool in place.
13. The sealant is inserted into the injector bore through the center hole in the bore repair too. The kit comes with four tubes; if you need more, they can be easily purchased. This sealant will flow into the crack and seal it, repairing an issue that otherwise would require a new head. You must use one full tube per cracked injector bore.
13. The sealant is inserted into the injector bore through the center hole in the bore repair too. The kit comes with four tubes; if you need more, they can be easily purchased. This sealant will flow into the crack and seal it, repairing an issue that otherwise would require a new head. You must use one full tube per cracked injector bore.
14. To obtain the pressure needed to force the sealant into the injector bore crack, hydraulic action is required. A simple grease gun is all that’s needed but a special tool in the kit ensures that you reach the proper pressure.
14. To obtain the pressure needed to force the sealant into the injector bore crack, hydraulic action is required. A simple grease gun is all that’s needed but a special tool in the kit ensures that you reach the proper pressure.
15. The sealant phase requires that your gauge read 500 psi for the start of the repair. The pressure is left on for 10 to 15 minutes and the pressure will drop over time. Once it reaches zero, you can move on to the next cylinder that needs repair.
15. The sealant phase requires that your gauge read 500 psi for the start of the repair. The pressure is left on for 10 to 15 minutes and the pressure will drop over time. Once it reaches zero, you can move on to the next cylinder that needs repair.
16. Once you have finished one head, you can button things up and move on to check and repair the other head. Caution! The crack sealant must be allowed to cure for a minimum of 24 hours, 72 hours if the temp is below 70 degrees F. Failure to do so will result in the leak returning. So do not even turn the key on as this pressurizes the fuel rails. Best to keep the battery disconnected. Don’t forget to replace any coolant hoses contaminated by the leaking fuel and it’s recommended to replace the O-rings on the intake manifold and the front engine cover too. These are also subject to contamination from fuel in the coolant.
16. Once you have finished one head, you can button things up and move on to check and repair the other head. Caution! The crack sealant must be allowed to cure for a minimum of 24 hours, 72 hours if the temp is below 70 degrees F. Failure to do so will result in the leak returning. So do not even turn the key on as this pressurizes the fuel rails. Best to keep the battery disconnected. Don’t forget to replace any coolant hoses contaminated by the leaking fuel and it’s recommended to replace the O-rings on the intake manifold and the front engine cover too. These are also subject to contamination from fuel in the coolant.
17. Here you see the contents of the Bullet Proof Diesel 6.0L Cylinder Head Repair Kit.
17. Here you see the contents of the Bullet Proof Diesel 6.0L Cylinder Head Repair Kit.
18. The Bullet Proof Diesel repair kit comes in a high-impact case for storage.
18. The Bullet Proof Diesel repair kit comes in a high-impact case for storage.
SOURCES:

Bullet Proof Diesel

480.247.2331

BulletProofDiesel.com

Domestic Diesel

909.664.7679

DomesticiDieselShop.com

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