Chrysler Full-Size Trucks 1989-1996 Repair Guide

Rocker Arms/Shafts

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REMOVAL & INSTALLATION



2.5L Engine

See Figure 1

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the cylinder head cover.
  4.  



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Fig. Fig. 1: Use a valve spring compressor tool to depress the valves-2.5L engine shown

  1. Rotate the crankshaft until the low point of the desired cam lobe is contacting the rocker arm.
  2.  
  3. Use the special valve spring compressor tool, or equivalent, depress the valve spring (without dislodging the keeper) and slide the rocker arm out.
  4.  

To install:
  1. Depress the valve spring with the compressor tool and install in reverse order, turning the camshaft as necessary.
  2.  
  3. Install the cylinder head cover.
  4.  
  5. Connect the negative battery cable.
  6.  

3.9L Engine

See Figures 2, 3, 4 and 5

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the cylinder head cover and gasket.
  4.  



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Fig. Fig. 2: Rocker arm location-left bank of the 3.9L engine;">

  1. Note the positioning of the oil notch and remove the rocker arms and shaft assembly from the head.
  2.  
  3. Disassemble the unit as required and replace all worn parts.
  4.  



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Fig. Fig. 3: Details of the rocker arm assembly-3.9L engine

On engines with exhaust valve rotators, the exhaust rocker arm must have relief for clearance.



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Fig. Fig. 4: Use a ratchet and the correct socket to unbolt the rocker arm assembly



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Fig. Fig. 5: Lift the rocker arm assembly from the engine and put it in a clean, safe location

To install:
  1. Make sure all rocker arms with an RH stamped on them are installed to the right of those with an LH. Install the assembly with the notch on the end of the shaft pointing to the engine centerline and to the rear of the right bank or to the front of the left bank. Make sure the longer stamped steel retainers are at the number 2 and 4 positions. Tighten the bolts evenly and gradually to 17 ft. lbs. (23 Nm).
  2.  
  3. Install the cylinder head cover.
  4.  
  5. Connect the negative battery cable and check for leaks.
  6.  

V8 and V10 Engines

See Figures 6, 7 and 8

The stamped steel rocker arms are arranged on one rocker arm shaft per cylinder head. Because the angle of the pushrods tend to force the rocker arm pairs toward each other, oilite spacers are fitted to absorb the side thrust at each rocker arm. The shaft is secured by bolts and steel retainers attached to the brackets on the cylinder head.



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Fig. Fig. 6: Details of the rocker arm assembly as installed in the V8 engines



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Fig. Fig. 7: Rocker arm design including location of the lubrication holes-V8 engines

  1. Disconnect the spark plug wires.
  2.  
  3. Disconnect the closed ventilation system and evaporative control system (if so equipped) from the cylinder head cover.
  4.  



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Fig. Fig. 8: Exploded view of the rocker arm assembly-V10 engine

  1. Remove each cylinder head cover and gasket.
  2.  
  3. Remove the rocker shaft bolts and retainer.
  4.  
  5. Remove each rocker arm and shaft assembly. Keep everything in order for installation in the original position.
  6.  

To install:
  1. Install the components in the same order as removed. For V8 engines, the notch on the end of both rocker shafts should point to the engine centerline and toward the front of the engine on the left cylinder head and toward the rear on the right side.
  2.  
  3. For 1989-92 V8 models: tighten the rocker arm bolts to 17 ft. lbs. (23 Nm).
  4.  
  5. For all 1993-96 models: tighten the rocker arm bolts to 21 ft. lbs. (28 Nm).
  6.  
  7. Install the cylinder head and cover gasket.
  8.  
  9. Connect the spark plug wires.
  10.  

Diesel Engine

See Figures 9, 10 and 11

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the cylinder head cover.
  4.  



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Fig. Fig. 9: Details of the rocker arm components-diesel engine

  1. Loosen the adjusting screw locknuts. Loosen the screws until they stop.
  2.  



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Fig. Fig. 10: Diesel engine pushrods

  1. Remove the 8mm bolt and 12mm bead bolt from the pedestal.
  2.  



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Fig. Fig. 11: Rocker arm bolt tightening sequence-diesel engine

  1. Remove the pedestal and rocker arm assembly. Remove the pushrods if necessary.
  2.  
  3. Remove the retaining ring and thrust washer.
  4.  
  5. Remove the rocker arm from the pedestal.
  6.  

Do not disassemble the rocker shaft and pedestal; they must be replaced as an assembly.

  1. Remove the locknut and adjusting screw from the rocker arm.
  2.  

To install:
  1. Install the adjusting screw and locknut.
  2.  
  3. Lubricate the shaft with oil and install the rocker arm to the shaft. Install the thrust washer and snapring.
  4.  
  5. Install the pushrods to the engine if they were removed.
  6.  
  7. Install the pedestal and rocker arm assembly to the head aligning the dowel in the pedestal with the dowel bore in the head. If the pushrod is holding the pedestal off of the head, turn the engine until the pedestal will set on the head without interference.
  8.  
  9. Lubricate the threads of the bolt with oil. Install and torque first to 29 ft. lbs. (40 Nm), then to 62 ft. lbs. (85 Nm) and finally to 93 ft. lbs. (126 Nm). If all of the pedestals were removed, follow the entire head bolt torque sequence including those head bolts that were not removed in this procedure.
  10.  
  11. Tighten the 8mm bolts of 18 ft. lbs. (24 Nm).
  12.  
  13. Adjust the valves.
  14.  
  15. Install the cylinder head cover with a new gasket. Tighten the bolts to 18 ft. lbs. (24 Nm).
  16.  
  17. Connect the negative battery cable.
  18.  

 
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