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    Ford Excursion, Expedition, Lincoln Navigator 2000-2005

    Rocker Arms

    Print

    Removal & Installation





    Click image to see an enlarged view

    Fig. Exploded view of the rocker arm assembly-diesel engines

    1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
    2.  
    3. Disconnect the ground cables from both batteries.
    4.  
    5. Remove the valve cover attaching screws and remove both valve covers.
    6.  
    7. Remove the valve rocker arm post mounting bolts. Remove the rocker arms and posts in order and mark them with tape so they can be installed in their original positions.
    8.  
    9. If the cylinder heads are to be removed, then the pushrods can now be removed. Make a holder for the pushrods out of a piece of wood or cardboard and remove the pushrods in order. It is very important that the pushrods be reinstalled in their original order. The pushrods can remain in position if no further disassembly is required.
    10.  

    To install:

    1. If the pushrods were removed, install them in their original locations. Make sure they are fully seated in the tappet seats.
      NOTE
      The copper colored end of the pushrod goes toward the rocker arm.

    2.  
    3. Apply a polyethylene grease to the valve stem tips. Install the rocker arms and posts in their original positions.
    4.  
    5. Turn the engine over by hand until the valve timing mark is at the 11:00 o'clock position, as viewed from the front of the engine. Install all of the rocker arm post attaching bolts and tighten to 20 ft. lbs. (27 Nm).
    6.  
    7. Install new valve cover gaskets and install the valve cover.
    8.  
    9. Install the battery cables, start the engine and check for leaks.
    10.  

    4.6L & 5.4L Engines
    1. Before servicing the vehicle, refer to the precautions section.
    2.  
    3. Disconnect the negative battery cable.
    4.  
    5. Remove the camshaft covers.
    6.  
    7. Position the piston of the cylinder being serviced at the bottom of its travel.
      NOTE
      Two different valve spring compressor tools are used for this procedure. Valve Spring Compressor (T91P-6565-A) is used on the exhaust camshaft and Valve Spring Compressor (T93P-6565-A) is used on the intake camshaft.

    8.  
    9. Compress the valve spring and remove the rocker arm.

      Click image to see an enlarged view

      Fig. Using the proper tool, compress the valve spring and remove the rocker arm-4.6L and 5.4L engine

    10.  

    To install:

    1. Position the piston of the cylinder being serviced at the bottom of its travel.
    2.  
    3. Apply clean engine oil to the rocker arm, valve stem tip and tappet bore.
      NOTE
      Valve tappet should have no more than 1 / 16 inch (1.5mm) of travel before installing the rocker arm.

    4.  
    5. Compress the valve spring using the correct tool and install the rocker arm.
    6.  

    1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
    2.  
    3. Disconnect the negative battery cable.
    4.  
    5. Remove the camshaft covers.
    6.  
    7. Position the piston of the cylinder being serviced at the bottom of its travel.
      NOTE
      Two different valve spring compressor tools are used for this procedure. Valve Spring Compressor (T91P-6565-A) is used on the exhaust camshaft and Valve Spring Compressor (T93P-6565-A) is used on the intake camshaft.

    8.  
    9. Compress the valve spring and remove the rocker arm.
    10.  

    To install:

    1. Position the piston of the cylinder being serviced at the bottom of its travel.
    2.  
    3. Apply clean engine oil to the rocker arm, valve stem tip and tappet bore.
      NOTE
      Valve tappet should have no more than 1 / 16 inch (1.5mm) of travel before installing the rocker arm.

    4.  
    5. Compress the valve spring using the correct tool and install the rocker arm.

      Click image to see an enlarged view

      Fig. Using the proper tool, compress the valve spring and remove the rocker arm-4.6L and 5.4L engine

    6.  

    6.0L Engines
    1. Before servicing the vehicle, refer to the Precautions section.
      CAUTION
      To prevent engine damage, always install new head bolts when installing the cylinder head, even if removing only one bolt. It will be necessary to install a new cylinder head gasket as well as all cylinder head bolts.

    2.  
    3. Remove the cylinder head.
      NOTE
      Be careful when removing the rocker arm. Do not lose the rocker arm steel ball.

    4.  
    5. Push down on the rocker arm. Pull out on the bottom releasing the ball.
    6.  
    7. Remove the steel ball from the rocker arm.
    8.  
    9. Remove the rocker arm clip from the fulcrum plate.
    10.  
    11. Clean and inspect all parts for pitting or scuffing. Install new rocker arm and valve bridges, as needed.
    12.  

    To install:

    1. Install the rocker arm clip on the fulcrum plate.
    2.  
    3. Place the steel ball in the rocker arm cup and lubricate with clean engine oil.

      Click image to see an enlarged view

      Fig. Place the steel ball in the rocker arm cup and lubricate with clean engine oil-6.0L engine

    4.  
    5. Push down on the rocker arm to compress the rocker arm clip. Insert the ball and release the pressure. Verify free movement of the rocker arm on the fulcrum.
    6.  
    7. Install the cylinder head.
    8.  

    6.8L Engine
    1. Before servicing the vehicle, refer to the precautions section.
    2.  
    3. Disconnect the negative battery cable.
    4.  
    5. Remove the camshaft covers.
    6.  
    7. Position the base circle of the camshaft lobe on the rocker arm to be serviced. Also, be sure the piston is not at the top of its travel near the valve.
    8.  
    9. Compress the valve spring and remove the rocker arm.

      Click image to see an enlarged view

      Fig. Compress the valve spring and remove the rocker arm-6.8L engine

    10.  

    To install:

    1. Position the base circle of the camshaft lobe over the place where the rocker arm is to be installed.
    2.  
    3. Apply clean engine oil to the rocker arm, valve stem tip and tappet bore.
    4.  
    5. Compress the valve using the special tool and install the rocker arm.
    6.  
    7. Install the rocker arm covers and the remaining components.
    8.  

    1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
    2.  
    3. Disconnect the negative battery cable.
    4.  
    5. Remove the camshaft covers.
    6.  
    7. Position the base circle of the camshaft lobe on the rocker arm to be serviced. Also, be sure the piston is not at the top of its travel near the valve.
    8.  
    9. Compress the valve spring and remove the rocker arm.
    10.  

    To install:

    1. Position the base circle of the camshaft lobe over the place where the rocker arm is to be installed.
    2.  
    3. Apply clean engine oil to the rocker arm, valve stem tip and tappet bore.
    4.  
    5. Compress the valve using the special tool and install the rocker arm.
    6.  
    7. Install the rocker arm covers and the remaining components.

      Click image to see an enlarged view

      Fig. Compress the valve spring and remove the rocker arm-6.8L engine

    8.  

    7.3L Engine


    Click image to see an enlarged view

    Fig. Exploded view of the rocker arm assembly-diesel engines

    1. Before servicing the vehicle, refer to the precautions section.
    2.  
    3. Disconnect the ground cables from both batteries.
    4.  
    5. Remove the valve cover attaching screws and remove both valve covers.
    6.  
    7. Remove the valve rocker arm post mounting bolts. Remove the rocker arms and posts in order and mark them with tape so they can be installed in their original positions.
    8.  
    9. If the cylinder heads are to be removed, then the pushrods can now be removed. Make a holder for the pushrods out of a piece of wood or cardboard and remove the pushrods in order. It is very important that the pushrods be reinstalled in their original order. The pushrods can remain in position if no further disassembly is required.
    10.  

    To install:

    1. If the pushrods were removed, install them in their original locations. Make sure they are fully seated in the tappet seats.
      NOTE
      The copper colored end of the pushrod goes toward the rocker arm.

    2.  
    3. Apply a polyethylene grease to the valve stem tips. Install the rocker arms and posts in their original positions.
    4.  
    5. Turn the engine over by hand until the valve timing mark is at the 11 o'clock position, as viewed from the front of the engine. Install all of the rocker arm post attaching bolts and tighten to 20 ft. lbs. (27 Nm).
    6.  
    7. Install new valve cover gaskets and install the valve cover.
    8.  
    9. Install the battery cables, start the engine and check for leaks.
    10.  

     
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