Series 60 cyl head quation.

Yeah, that should work just fine.

 

No, egr intake manifold has to be used on egr head and non egr intake on non egr head because the intake ports are different size. You will need to use the sensors that go with the engine regaurdless of which head you use. If you use egr head put a 1/4 inch pipe to hose barb in the intake and a piece of hose to the old boost sensor. And just screw the old IAT into an open port. The exhuast ports are the same on both heads and will accept either exhaust manifold.

 

I recently had an issue similar to this with a set of 795 jakes. Turned out the cylinder wall for the slave pistons were worn and had grooves in it and stopped them from full motion. Try removing the piston and feeling the bore where they slide in with your finger and see if you feel a lip.