Tom, thanks for the link to those threads they made good reading. I do have to admit that when Skhochay said these heads had a problem with cracking, i was thinking he was talking about cracks in, and around the combustion chamber, not cracks in the valve cover mounting rail.I suspect this is what @skhochay is referencing. I'm not sure I would consider it 'typical' but not an isolated incident. I had cracks around number 2 and number 5.
External cracked cylinder head - Leaking oil!
Okay everyone, I have a new motor with about 2,000 miles on it. Everything seemed to be going fine. Motor was rebuilt by a reputable shop...head was rebuilt by someone who I thought was reputable. Now I do not really think this crack is something that could've been avoided. Just bad luck really...forum.ih8mud.com
Hairline Cracks In Cylinder Head -- Advice Please!
Greetings, first off great site and forgive me if this issue has been covered. I recently bought a locked '96 with 73K miles (!!!) on it. Truck runs great, no problems, no rough idle, no power loss. The previous owner mentioned he'd replaced the head gasket. This seems to be pretty typical...forum.ih8mud.com
After looking at those threads there is no way I'd replace one of those heads. I'd seal those cracks up and keep running the head.
I've used Loctite 290 for years in my shop to seal up small porosity holes, and cracks in Aluminum castings with great success.
So I'd clean off as much oil as i could around the crack with brake cleaner. Then I'd use a Map torch to heat up a small area around the crack to slightly expand it. Plus the heat will help evaporate any left over brake cleaner inside the crack.
Then I'd fill the crack with some Loctite 290 that will wick it's way deep down inside the crack, then let the Loctite cure over night before running the engine.