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Rocker Arm: Removal

WARNING: This page is about a different car, the 2008 Ford Econoline, 2008 Ford E450 Super Duty, and 2008 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
  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 6 stud bolts, 5 bolts and valve cover.
    • Clean and inspect the valve cover gasket. Install a new gasket if necessary.
    3. Fig 1: Identifying RH Stud Bolts, Bolts & Valve Cover
    GF0044560Courtesy of FORD MOTOR CO.
  3. Remove the RH high-pressure oil rail-to-valve cover gasket.
    4. Fig 2: Identifying High-Pressure Oil Rail-To-Valve Cover Gasket
    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 2 of the 4 bolts that attach the damper to the front of the crankshaft.
    6. Fig 3: Locating Dowel Hole In The Vibration Damper
    GF0005730Courtesy 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.
    7. Fig 4: Dowel Hole At 12 O'clock Position
    GF0005731Courtesy of FORD MOTOR CO.
    NOTE: If servicing all rocker arms, or any of the rocker arms for cylinders 1, 2, 7 and 8, the remainder of this 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 this 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 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. Remove the crankcase-to-head tube(s).
    • Remove and discard the D-ring seals.
    10. Fig 5: Crankcase-To-Head Tube
    GF0005912Courtesy of FORD MOTOR CO.
    NOTE: LH cylinder head shown, RH cylinder head similar.
    NOTE: Do not remove the oil rail end plugs or acoustic wave attenuator port fitting. Service parts are not available to support these components.
  10. Remove the 9 bolts and the high-pressure oil rail.
    11. Fig 6: Identifying Bolts And High-Pressure Oil Rail
    G03887377Courtesy of FORD MOTOR CO.
    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 the High Pressure Supply Tube Remover, remove the lower crankcase-to-head tube.
    • Remove and discard the D-ring seal.
    12. Fig 7: Identifying Special Tool (303-1164)
    G04519461Courtesy of FORD MOTOR CO.
    NOTE: Do not attempt to apply battery voltage to the fuel injector or damage to the fuel injector may occur.
  12. Using the Injector Connector Release Tool, push the fuel injector electrical connector out of the rocker arm carrier.
    13. Fig 8: Pushing Fuel Injector Electrical Connector Out Of Rocker Arm Carrier
    GF0011857Courtesy of FORD MOTOR CO.
  13. Prior to removing the injector assembly, insert clean shop towels in the oil drain holes adjacent to each glow plug.
    14. NOTE: To prevent engine damage, do not use air tools to remove the fuel injectors.
    NOTE: There is no need to drain the fuel rail.
  14. Remove the bolt, the fuel injector hold down and the fuel injector.
    • Remove and discard the O-ring seals and copper washer.
    15. Fig 9: Identifying Fuel Injector Hold-Down Bolt
    G03887381Courtesy of FORD MOTOR CO.
    NOTE: Make sure the notch in the base is aligned in the hold-down clamp.
  15. Insert the injector hold-down clamp into the Rocker Arm Service Tool base.
    16. Fig 10: Inserting Injector Hold-Down Clamp Into Rocker Arm Service Tool Base
    GF0044561Courtesy of FORD MOTOR CO.
    NOTE: While centering the base between the 2 bridges, snug the hold-down bolt only. Do not tighten it or engine damage can occur.
  16. Install the injector hold-down clamp and Rocker Arm Service Tool base in between the bridges as if you are installing an injector.
    17. Fig 11: Injector Hold Down And Special Tool Base
    GF0005733Courtesy of FORD MOTOR CO.
    NOTE: 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.
  17. Install the Rocker Arm Service Tool plate on top of the bridges with the small point of the plate in between the exhaust rocker and bridge. Install the Rocker Arm Service Tool bolt and compress the valve springs until the plate contacts the top of the tool base.
    18. Fig 12: Compressing Valve Spring
    GF0005735Courtesy of FORD MOTOR CO.
    NOTE: When removing the rocker arm, be careful not to drop the ball from the fulcrum plate or rocker arm socket.
  18. 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.
    19. Fig 13: Locating Rocker Arm Retaining Clip
    G03887385Courtesy of FORD MOTOR CO.
    NOTE: 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.
  19. Remove the push rod.
    • Inspect each push rod for wear and deposits which may restrict the flow of oil into the rocker arm assembly. Install new push rods as necessary.
    • Check the push rod for flatness by rolling them on a flat surface if not within specification. Install new push rods as necessary. For additional information, refer to SPECIFICATIONS .
    20. Fig 14: Identifying Push Rod
    GF0034905Courtesy of FORD MOTOR CO.
  20. With the rocker arms removed, remove the Rocker Arm Service Tool bolt and the special tool plate to gain access to the valve bridges.
    21. Fig 15: Special Tool Plate Installed On Top Of The Bridges
    GF0005737Courtesy of FORD MOTOR CO.
    NOTE: Mark the location of the valve bridges before removing.
  21. Remove the valve bridges.
    • Inspect the valve bridges for wear or damage and install new as needed.
    22. Fig 16: Identifying Valve Bridges
    G03887388Courtesy of FORD MOTOR CO.
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