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Replaced mine when I rebuilt the engine and never had a problem.

I didn't just rebuild. I BUILT it.

0.040 bore
SS psitons
SS OS valves
270.430 cam
hv oil pump
bored TB
gasket matched intake
disabled EGR (not for performance, but for being cheap... It smacked the firewall when reinstalling the engine cracking the pipe. I just blocked it off instead of paying $$$$$ for a new one)

The other peice to my equation is environment... I couldn't keep the engine cool enough when I lived in Florida. ***poof*** Now I can't keep it cool enough when pulling grades in the Alps. Or when rolling 100+ on the Autobahn. Numerous excessive heat cycles are causing my failures. None happened during an overheat, but I attribute the eventual failure to excessive heat.

I haven't ordered my new gasket yet... I can't afford everything else I am going to do at the same time. I am replacing the radiator with a HD V6 one, and adding a digital temp guage, so I never have to go through this again.

"A young man who does not have what it takes to perform military service is not likely to have what it takes to make a living." - John F. Kennedy

Proud owner of an 88 Montero (with a blown engine).