Head is off to replace head gasket after blowing antifreeze out the radiator seam. This is the first time the head has been off (19 years & 194k miles- I am the original owner).
Pictured below is the crack I found on #1 (using dye penetrant). #2 Also has a similar crack. The other cylinder cracks (3 thru 6) stop before the valve seat.

Is this fixable or should I be looking for a new head?

 

Run it.

Mines cracked in 4 spots with no issues

 

GET ANOTHER HEAD GRUMPY JOHN 4X4

 

Since you already have it off I would say just get another one that way you have no worries. Just remember you will need another set of injectors (7mm). It is a perfect time to upgrade to a "big" set.

 

the seat would have to be replaced if you wanna run it again. only problem is, the seats in the head are integral and new ones would have to be pressed in. not quite as strong as the integral seats. alabama cylinder heads can get you a new 7mm head for about $450. i pulled mine at over 500K and had pinhole sized cracks on a couple seats. they might've only been surface cracks and if they were, they're probably gone after the seat grinding was done. other guys have ran their heads with the cracks and have no issues. i'd say give it a go. as long as the crack isn't exposing a water jacket or oil passage that would disappoint you yet again. i can however say that one guy put his head back on with some cracks and it ended up being a dud. he had to do the work twice and he bought a new head from alabama cylinder head.

 

Sounds like I am getting a new head. Anyone had issues with the ACH head (how many miles have you put on it)? Is there any difference between the aftermarket heads (some seem to offer a longer warranty)?

 

I've not seen anything bad about ACH head..

 

I had 6 cracks in the head of my nonIC 91, all right where yours are, all about 3-4x that size. Guy at the machine shop said he'd seen Case tractors with bigger cracks run without issue. I ran mine another 60K before selling the truck. Still outran the PSDs and ricers, still got 20+mpg, etc. If you arent planning on going all out on power, and if money is an issue (I wouldnt be able to come up with $500 right now), I'd say you'd be fine like it is. If you have the cash to spare, get a new one, and keep that one for a back up, or sell cheap.....

 

Update - Have a new ACH 7mm head (replacing cracked 9mm head), Bosch 190 injectors (PDP) and Cummins upper gasket set.
There are several sets of various thickness copper sealing washers.
Which do I want to use?
At this point I am not real interested in increased performance - more towards reliability. Thanks

 

I would use the thinnest.

 

Medium washers are the right ones, I believe they are 0.040".

 

Thanks for all the help.
Project is progressing - head back on, lines, exhaust manifold, valves adjusted. Cooling and belt drive stuff left to do.
Does any body know the torque for the band clamp between the turbo and down pipe? Thanks

 

74 in-lbs.

 

Please keep us posted about the new ACH, will ya....

 

Update - Have about 400 miles to date and no problems with the ACH head. Thanks for all the help.