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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 799 (Engine - 6.0L Diesel -- E350 & E450) >> In-Vehicle Repair >> Rocker Arm >> Removal

Rocker Arm: Removal

WARNING: This page is about a different car, the 2005 Ford RV Cutaway, 2005 Ford Econoline, 2005 Ford E450 Super Duty, and 2005 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

    All vehicles 

  1. Remove the engine from the vehicle. For additional information, refer to ENGINE .
    2. NOTE: Mark the location of the stud bolts.
  2. Remove the RH stud bolts, bolts and valve cover.
    • Clean and inspect the valve cover gasket, replace if necessary.
      Fig 1: Removing RH Stud Bolts
      G03887372Courtesy of FORD MOTOR CO.
  3. Remove the RH high-pressure oil rail-to-valve cover gasket.
    Fig 2: Identifying High-Pressure Oil Rail
    G03887197Courtesy of FORD MOTOR CO.
  4. If replacing rocker arms on the LH side, remove the protective covering from the LH cylinder head.
  5. Locate the dowel hole in the vibration damper.
    • The hole is located between two of the four bolts that attach the damper to the front of the crankshaft.
      Fig 3: Locating Dowel Hole
      G03887374Courtesy of FORD MOTOR CO.
  6. Rotate the crankshaft until the dowel hole is at the 12 o'clock position.
    • The No. 1 piston should be on the compression stroke. Wiggle the rocker on the No. 1 cylinder to verify both intake and exhaust rocker arms are able to move freely. If the intake and exhaust rocker arms do not move freely, rotate the crankshaft one complete revolution. You are now positioned to service the rocker arms for cylinders 1, 2, 7 and 8.
      Fig 4: Rotating Crankshaft
      G03887375Courtesy of FORD MOTOR CO.
    7. NOTE: If servicing all rocker arms, or any of the rocker arms for cylinders 1, 2, 7 and 8, the remainder of the procedure must be performed before rotating the crankshaft to prepare the engine to service cylinders 3, 4, 5 and 6.
  7. If required, skip Step  8 and complete the rest of the procedure, for rocker arms on cylinders 1, 2, 7 and 8.
    8. NOTE: All service for cylinders 1, 2, 7 and 8 must be completed before rotating the crankshaft to prepare the engine to service cylinders 3, 4, 5 and 6.
  8. If you are not servicing cylinders 1, 2, 7 and 8 or if service to those cylinders has been completed, rotate the crankshaft one complete revolution to service the rocker arms for cylinders 3, 4, 5 and 6.
    • Complete the rest of this procedure for rocker arms on cylinders 3, 4, 5 and 6.

    9. Late build 

  9. Remove the crankcase-to-head tube.
    • Remove and discard the D-ring seals.
      Fig 5: Removing D-Ring Seals
      G03887376Courtesy of FORD MOTOR CO.

    10. All vehicles 

    NOTE: Do not remove the oil rail end plugs or acoustic wave attenuator port fitting. Service parts are not available to support the components.
    Fig 6: Identifying Bolts And High-Pressure Oil Rail
    G03887377Courtesy of FORD MOTOR CO.
  10. Remove the bolts and the high-pressure oil rail.

    11. Late build 

    CAUTION: Use care not to deform the lower crankcase-to-head tube during removal. If the tube is damaged, a new tube must be installed.
    NOTE: Use a shop towel and metal brake parts cleaner to remove the oil residue prior to removing.
  11. If the crankcase-to-head tube separated, using a pair of soft-jawed pliers, remove the lower crankcase-to-head tube.
    • Remove and discard the D-ring seal.
      Fig 7: Removing Lower Crankcase-To-Head Tube
      G03887378Courtesy of FORD MOTOR CO.

    12. Early build 

    NOTE: The rings on the crankcase-to-head tube are tube used to pry the tube assembly from the branch tube assembly or the oil rail assembly.
  12. Remove the crankcase-to-head tube assembly.
    • Remove and discard the D-ring seals.
      Fig 8: Identifying Crankcase-To-Head Tube
      G03887379Courtesy of FORD MOTOR CO.

    All vehicles 

    13. CAUTION: Do not attempt to apply battery voltage to the fuel injector or damage to the fuel injector will occur.
    Fig 9: Removing Fuel Injector Electrical Connector
    G03887380Courtesy of FORD MOTOR CO.
  13. Using the special tool, push the fuel injector electrical connector out of the rocker arm carrier.
  14. Prior to removing the injector assembly, insert clean shop towels in the oil drain holes adjacent to each glow plug.
    15. CAUTION: To prevent engine damage, do not use air tools to remove the fuel injectors. The snap ring that extracts the injector can dislodge and fall into the oil drain hole.
    CAUTION: Failure to account for all snap rings or pieces prior to placing the vehicle back in service can cause engine damage. A missing snap ring can be ingested into the lube oil system, causing serve engine damage.
    NOTE: There is no need to drain the fuel rail.
    Fig 10: Locating Bolt, Fuel Injector Hold-Down Clamp And Fuel Injector
    G03887381Courtesy of FORD MOTOR CO.
  15. Remove the bolt, the fuel injector hold-down and the fuel injector.
    16. NOTE: Make sure the notch in the base is aligned in the hold-down clamp.
    Fig 11: Inserting Injector Hold-Down Clamp
    G03887382Courtesy of FORD MOTOR CO.
  16. Insert the injector hold-down clamp into the special tool base.
    17. CAUTION: While centering the base between the two bridges, snug the hold down bolt only. Do not tighten it or engine damage can occur.
    Fig 12: Installing Assembly
    G03887383Courtesy of FORD MOTOR CO.
  17. Install the assembly in between the bridges as if you are installing an injector.
    18. CAUTION: Only use hand tools to compress the valve springs. Do not use power tools or engine damage can occur.
    NOTE: If the rocker arm is severely worn, insert a small pry bar between the exhaust rocker arm and bridge to gain clearance by compressing the valves slightly.
    Fig 13: Installing Special Tool
    G03887384Courtesy of FORD MOTOR CO.
  18. Install the special tool plate on top of the bridges with the small point of the plate in between the exhaust rocker and bridge. Install the special tool bolt and compress the valve springs until the plate contacts the top of the tool base.
    19. NOTE: When removing the rocker arm, be careful not to drop the ball from the fulcrum plate or rocker arm socket.
  19. Disengage the rocker arm from the push rod. Then rotate the rocker arm out while compressing down on the rocker arm retaining clip.
    • Remove and discard the rocker arm retaining clip.
    • Repeat the step for the other rocker arm.
      Fig 14: Disengaging Rocker Arm
      G03887385Courtesy of FORD MOTOR CO.
    20. CAUTION: To prevent engine damage, keep the push rods in the order in which they were removed. Install the push rods back in their original positions.
  20. Remove the push rod.
    • Inspect each push rod for wear and deposits which may restrict the flow of oil into the rocker arm assembly, replace as necessary.
    • Check the push rod for flatness by rolling them on a flat surface if not within specification, replace as necessary.
      Fig 15: Removing Push Rod
      G03887386Courtesy of FORD MOTOR CO.
  21. With the rocker arms removed, remove the special tool bolt and the special tool plate to gain access to the valve bridges.
    Fig 16: Removing Special Tool Bolt
    G03887387Courtesy of FORD MOTOR CO.
  22. Remove and discard the valve bridges.
    Fig 17: Removing Valve Bridges
    G03887388Courtesy of FORD MOTOR CO.
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