I too have had the same problem with my 4Runner. Yes, the head gaskets were replaced some time ago by the previous owner under the recall, however, I have found myself in the same position as the prior. BLOWN AGAIN! I've always been a great supporter of Toyota Vehicles, but I must say, I've lost faith. Now, I am facing roughly $2000.00 to repair the truck and no longer want to keep it. Is there some way that the dealership will cover the costs? Will they fix it a second time. I maintain my 4runner and believe that it is yet again, a manufacturing issue. Any advice?
I have a friend who was in the exact position you are facing. He bought his '92 4Runner off a guy who had the entire 3.0L motor replaced by ToyMoCo at 250,000KM. 90,000KM later, the HG blew again, and that was not covered by Toyota Canada. Cost him about $3500.
I have an '88 4x4 pickup with the 3.0L (first year of production), and apparently the HG was made from asbestos, so it's supposedly not as prone to failure as the graphite ones in the '89-95 models. I have almost 300,000KM on mine, and it still runs great. If the HG was to go on mine, I would just junk it.