My '96 2.7L is in the shop. Blown head gasket @150,000miles. 2nd time since I got the truck. 1st time was somewhere @95-100k miles. Is this a common issue with the 2.7's, or maybe certain years of 2.7's? There's no way I'd get rid of my truck, but I don't want to be spending $1100 to $1300 every 50k miles. Can anything be done to prevent future "blowouts"? 1st time was repaired by dealer using oem parts.

No, it definitely not a common thing. Especially twice within 50K. I've got nearly 200K on my junk and no head gasket problems. Make sure that the head isn't warped, that your motor isn't running excesively hot (or lean), etc.

As Phil advised, check the flatness of the head. Normally the head is planed after a head gasket failure to alleviate any inconsistencies in the mating surface.

From my school experience and talking with career Toyota techs, the only somewhat common malady that the 2.7 can experience is burnt valves, likely caused by a cracked exhaust manifold that has been avoided too long.

I haven't heard of anyone who has had more trouble with their 2.7, but I still think it's a great engine. Replaced a burnt valve at around 80-90k, a rear main seal at 100k, and rebuilt the motor at 113k. After the burnt valve I replaced both oxygen sensors, and have replaced the TPS, MAF, EGR, IAC, knock, and probably other sensors over the past three years.
Now at 130k or so and going strong.

I haven't heard of anyone who has had more trouble with their 2.7, but I still think it's a great engine. Replaced a burnt valve at around 80-90k, a rear main seal at 100k, and rebuilt the motor at 113k. After the burnt valve I replaced both oxygen sensors, and have replaced the TPS, MAF, EGR, IAC, knock, and probably other sensors over the past three years.
Now at 130k or so and going strong.

Holy crap! That's a lot of stuff to replace at only 130k for any motor.
My 22 year old 275k 22re hasn't even had all that stuff replaced, but the head has been rebuilt and head gasket replaced once since. Maybe headgaskets are a 4cyl thing?

The only engine stuff I've replaced on my 255k 3.4L (T100) are valve cover gaskets, water pump, O2 sensor, and vapor pressure sensor (and of course a couple timing belts). And I don't baby it at all.

I love the 3.4. Its a tank!

That's why I didn't hesitate to buy my 4runner with 224k on it!

Holy crap! That's a lot of stuff to replace at only 130k for any motor.

Yes it is, but considering the many cold-water dunkings, being coated in mud, cold weather abuse, etc. it could have been worse. The rebuild was necessitated by washed cylinders. It was running rich for a while and before I could find the cause it had developed a dead hole, cylinder three.

well, I'll be sure that the work performed is done competently. I trust the shop that'll be doing the repair. I don't think I drive the truck too hard, as I used to drive my previous trucks/cars like I stole 'em. No burn-outs, 5k rpm clutch dumps or any craziness now...never get into the red. When the last blown head gasket occurred, I had only put 5k miles on the truck since bought at 90k miles, but previous owner(s) may have driven like pricks. #3 cyl. had zero compression, so I'll ask the shop if it's the same cyl. this time. It's good that no one's confirming my fear of an early design flaw. Hopefully, if I blow another head gasket in another 55k miles, the truck will by that time be a trail-only rig & I can do a swap to a 3.4 or a Tundy v-8.

well, got roctaco back yesterday. Has a brand new, factory head. Everything in the old head was reuseable. Machine shop found four cracks in old head. Could have repaired, but the expense involved made a new head sound better to me. Truck ran good when I picked up, but had small exhaust leak (where EGR pipe mates to Downey header). Truck is back at shop for that & they said they'd recheck to be sure everything else is cool. Hopefully I'll get to take my son for a short outing this weekend out by Holy Jim Cyn. or somewhere nearby. Anyone interested in joining for just some minor foolin' around can pm me. Also, I'll be looking forward to a full day at TDS in March. Later guys.

nearly 200k on my 2.7 daily driver and the only thing replaced on it was a starter when i first got it 5 years ago. there is definetly some kind of problem related to you blowing those head gaskets especially within that short distance. id do as you said and take it to someone who knows what there doing and explain the situation.:confused:

No, it is not a common problem, I had to special order a head gasket for my 3rz, I live in phoenix and contacted 4 dealers and all the parts houses none of them stock that gasket. The good news is if you loosen your intake and exhaust properly you can reuse those gaskets. If the valve cover isnt leaking reuse that too!!! cost about 50$

The shop used a doubled gasket to fix the exhaust leak at the EGR-header connection....not the ideal solution but it's working for now. I'll re-tighten the bolts again & hopefully it will keep from blowing them out. That connection has always been prone to blowing out gaskets anyway.
Went out to Holy Jim Canyon Saturday morningin the rain & had a great time. It's not a really technical wheeling spot, more like a roadside play area. Definitely fun in the rain & has a few failry deep water pools. Now I'm really looking forward to TDS. Later.