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That amount of sludge indicates a cracked head, or a blown head gasket. That's it, no more diagnosis needed. You should stop driving the truck. Coolant in the oil will destroy the bearings in short order.
When you pull the heads don't be in a hurry to scrape the gaskets. Examine them carefully, the remnants on the heads and on the block. Check the fire rings. You want to see if there is a failure in the gasket.
One of the cylinders will be fouled. Many believe that the bad cylinder will be clean. My experience is that the bad cylinder is dirty from misfiring and trying to burn glycol. Regardless you'll see it. That cylinder head should be tested even if you find a gasket failure.
You have some work ahead of you. Good luck with it.
If he had a head that was sucking that amount of coolant it would be very obvious and run like crap. The 3.9 rarely blow heads unless it was abused or neglected. Plus you tested it a number of times already correct pulling the plugs is a very good idea I would do that. If you pull the dipstick out what does it look like? A compression test would be a good idea also.
That amount of sludge indicates a cracked head, or a blown head gasket. That's it, no more diagnosis needed.
What sludge? The milky mix is indicative of moisture in the oil but it from the location it is very likely due to the engine not getting hot long enough to burn off the moisture.
Anyone with a 4.7 knows exactly what I mean, you see it every winter.
It could be an intake manifold leak too. There is coolant flowing from the heads into the manifold.
What sludge? That goo in the photo in post 17. That's not normal, ever.
My guess is a blown head gasket. And that's why I mentioned taking it apart, and to immediately stop driving the truck.
Of course my guess is only based on forty years of automotive experience and repair.
He must have added in the Pic later never saw it till now yea that looks bad but it could still not be a blown head. Coolant is getting into the oil thats for sure. I have seen a post a year ago where the back of the water pump was leaking in to the engine. The pump attaches to the timing chain cover the cover is part of the pump and a small hole rotted through the cover allowing coolant to enter.
I cant remember the engine this happened too but this may be the same problem.
This pic shows it this is a 3.9 timing chain cover
When you replaced the gasket, did you use thread sealer on all the bolts? Several go into the water jacket, and if you didn't use thread sealer, they'll leak and you'll chase problems no end.
Or a leak in this area I say pull off the pump and give it a good look over.
Dodgevity, that was the test I ran. I just called it a block test (at the beginning of the thread). It passed with flying colors. I tried it three different times, one of which was right after I drove it.
00DakDan, I am beginning to wonder if the intake manifold gasket was allowing the coolant in!
As far as condensation, I really only drive 30 miles to and from work...not a lot of short drives which many have concluded caused that amount of milkiness.
That said, I have an update. I decided to pull the heads and have them cleaned and magnafluxed. I'm still waiting on the results. All I could really see on the head gasket was a potential leak between cylinders. It was pretty boogered up after the nasty coolant/oil dumped on them when I pulled the heads off. I'll wipe them down and see if I have any other adverse indications. The pic here is the underside of the intake manifold. More of the same nastiness!
While I'm waiting to hear back from the machine shop, I've started cleaning off all the parts. I noticed a good amount of wear where the pushrod and rocker arm meet (maybe caused by all the coolant in the oil). I think it's enough to warrant new rockers and pushrods. Does anyone have strong opinions on what type to go with? I'm leaning toward a straight stock replacement because I don't want to dump more money into this truck than I need to. I also see many are upgrading to roller rockers. Do and of you know of any reputable suppliers for these parts?
