300, Magnum, 2005

Rocker Arms & Shafts

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Removal & Installation



3.5L Engine
Assembly


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Fig. Rocker arms assembled. (1) contact pads, (2) dowel pins, (3) pedestals, (4) rollers-3.5L engine

  1. Before servicing the vehicle, refer to the Precautions section.
    WARNING
    Do Not remove lash adjuster from rocker arm assembly. Damage to the adjuster and rocker arm will result. New dowel pins must be installed when reassembling.

  2.  
  3. Install the rocker arms, and pedestals onto the shaft.
  4.  
  5. Install dowel pins. Dowel pins pass through the pedestal into the exhaust rocker shafts.
    NOTE
    Dowel pins should be pressed in until they bottom-out against the rocker shaft in the pedestal.


    NOTE
    Rocker arm and shaft assembly can be installed either prior to or after (preferred) cylinder head installation.

  6.  

Disassembly


Click image to see an enlarged view

Fig. Dowel pin assembly-3.5L engine

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove dowel pin using a 4 mm screw, nut, spacer, and washer installed into the pin. Thread the screw into the pin, then loosen the nut on the screw. This will pull the dowel out of the shaft support. Do not reuse dowel pins. Remove the rocker arms and pedestals in order.
  4.  
  5. Check the rocker arm mounting portion of the shafts for wear or damage. Replace if damaged or heavily worn.
  6.  
  7. Check shaft oil holes for clogging with small wire, clean as required.
  8.  

Inspection

NOTE
To prevent air ingestion into lash adjusters, avoid turning rocker arm assembly upside down.


WARNING
Do not allow rocker arm assembly to rest on lash adjusters, as damage may occur to lash adjuster and plastic retainer.

The intake and exhaust rocker arms are different. They should be identified before disassembling the assembly.

  1. Check rocker arms for wear or damage:

    Roller scuffing or wear
     
    Shaft bore scuffing or wear
     
    Swivel pad on lash adjuster missing or broken
     
    Rocker arm showing signs of fatigue or cracking
     
    Roller axle protruding from arm
     

  2.  
  3. Replace assembly as necessary if any rocker arms shows signs of wear.

    Click image to see an enlarged view

    Fig. Hydraulic lash adjusters. (1) plunger, (2) contact pads, (3) roller-3.5L engine

  4.  

Installation


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Fig. Rocker shaft bolt torque sequence-3.5L engine

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Rotate camshaft gears to the position shown (1, 8, and 9) in. With the camshaft gears in these positions the lobes are in a neutral position (no load to the valve). This will allow the rocker arm shaft assembly to be tightened into position with little or no valve spring load on it.
  4.  
  5. Install the rocker arm and shaft assembly making sure that the identification marks face toward the front of engine for left head and toward the rear of the engine for right head.
  6.  
  7. Tighten rocker arm/shaft assembly bolts in sequence to 23 ft. lbs. (31 Nm).
  8.  
  9. Install the cylinder head cover.
    1. Connect the ignition coil electrical connectors.
    2.  

  10.  
  11. Install upper intake manifold.
  12.  
  13. Connect negative battery cable
  14.  

Removal

WARNING
The rocker arm shafts are hollow and are used as lubrication oil passages. The rocker arm and shaft assembly on the RIGHT side of the engine has an oil passage hole from the cylinder head to the third rocker shaft support. The rocker arm shaft assembly on the LEFT side of the engine has an oil passage hole from the cylinder head to the second rocker shaft support.


WARNING
Do not start or run engine with cylinder head cover removed from the engine. Damage or personal injury may occur.



Click image to see an enlarged view

Fig. Rocker arm assemblies-3.5L engine

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect and isolate the negative battery cable.
  4.  
  5. Remove the upper intake manifold from the engine.
  6.  
  7. Cover lower intake manifold with a suitable cover during service.
  8.  
  9. Remove the cylinder head cover.
  10.  
  11. Identify the rocker arm assembly and rocker arms before disassembly.
  12.  
  13. Remove rocker arm assembly bolts.
  14.  
  15. Remove rocker arm assembly.
    NOTE
    To prevent air ingestion into lash adjusters, avoid turning rocker arm assembly upside down.


    WARNING
    Do not allow rocker arm assembly to rest on lash adjusters, as damage may occur to lash adjusters and/or plastic retainers.

  16.  

5.7L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove cylinder head cover.
  4.  
  5. Install pushrod retaining plate special tool 9070.

    Click image to see an enlarged view

    Fig. Pushrod retaining tool-5.7L engine



    Click image to see an enlarged view

    Fig. Rocker shaft loosening/tightening sequence-5.7L engine

  6.  
  7. Loosen the rocker shafts using the sequence provided.
    NOTE
    The rocker shaft assemblies are not interchangeable between intake and exhaust. The intake rocker arms are marked with an -I-.

  8.  
  9. Remove the rocker shafts. Note location for reassembly.
    NOTE
    The longer push rods are for the exhaust side, and the shorter push rods are for intake side.

  10.  
  11. Remove the pushrods. Note pushrod location for reassembly.
    WARNING
    Do not remove the retainers from the rocker shaft. The assembly tangs at the bottom of the retainers can be damaged, causing the assembly tangs to break off, and get into the engine.



    Click image to see an enlarged view

    Fig. Assembly tangs (1), retainers (2), rocker arm (4)-5.7L engine

  12.  

To install:


NOTE
The longer push rods are for the exhaust side, and the shorter push rods are for intake side.

  1. Install the push rods in the same order as removed.
  2.  
  3. Install the pushrod retaining plate special tool 9070.
    WARNING
    Ensure that retainers and rocker arms are not overlapped when torquing bolts.


    NOTE
    Verify that pushrod is installed into rocker arm and tappet correctly while installing rocker shaft assembly. Recheck after rocker shaft has been torqued to specification.


    NOTE
    The rocker shaft assemblies are not interchangeable between intake and exhaust. The intake rocker arms are marked with the letter -I-.

  4.  
  5. Install rocker shaft assemblies in the same order as removed.
  6.  
  7. Tighten the rocker shaft bolts to 16 ft. lbs. (22 Nm) torque, using the sequence provided.
    WARNING
    DO NOT rotate or crank the engine during or immediately after rocker arm installation. Allow the hydraulic roller tappets adequate time to bleed down (about 5 minutes).

  8.  
  9. Remove pushrod retaining plate special tool 9070.
  10.  
  11. Install cylinder head cover.
  12.  

 
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