Chrysler Full-Size Trucks 1997-2000 Repair Guide

Rocker Arms

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REMOVAL & INSTALLATION




NOTE
Valve train components must be reinstalled in their original locations. Lay out and tag all components to ease assembly.

2.5L, 3.9L, 5.2L, 5.9L, 8.0L Gasoline Engines
  1. Remove the valve cover(s).
  2.  
  3. On the 2.5L engine, adjacent rocker arms are linked by a bridge. Loosen paired bolts evenly, and then remove bolts, bridge, pivot assembly and rocker arms.
  4.  
  5. On other models, loosen the rocker arm bolt and remove the bolt, pivot assembly and rocker arm. V-10 engines have a retainer beneath the rocker arms.
  6.  
  7. Remove the pushrods, if required. Note locations of each for reassembly.
  8.  

To install:

  1. On the V-6 and V-8 engines, rotate the crankshaft until the "V6" or "V8" mark lines up with the TDC mark on the timing chain case cover.
  2.  
  3. Clean and lubricate all parts.
  4.  
  5. Be sure the pushrods are seated in the tappets.
  6.  
  7. Apply clean engine oil to the pushrod tip and to the rocker arm pivot.
  8.  
  9. Tighten rocker arm bolts to 21 ft. lbs. (28 Nm). On the 2.5L engine, tighten the adjacent bolts gradually until the proper torque is reached.
  10.  


WARNING
Do NOT rotate or crank the engine during or immediately after rocker arm installation. Allow the hydraulic tappets about five minutes to bleed down.



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Fig. 2.5L engine rocker arm assembly



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Fig. 5.2L engine rocker arm assembly



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Fig. Remove a rocker arm bolt-5.2L engine shown



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Fig. Rocker arm assembly-5.2L engine shown



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Fig. Removing a pushrod. Be sure to note location for reassembly. A cardboard box with a hole for each pushrod will do the trick

4.7L Engine

NOTE
Rocker arm removal requires the use of special tool, mfg. P/N 8516.

  1. Disconnect the battery negative cable.
  2.  
  3. Remove the cylinder head cover(s).
  4.  
  5. Rotate the crankshaft so that the piston of the cylinder to be serviced is at Bottom Dead Center (BDC) and both valves are closed.
  6.  
  7. Use special tool 8516 to depress the valve and remove the rocker arm.
  8.  
  9. Repeat for each rocker arm to be serviced.
  10.  


NOTE
Keep all valve train components in order for reassembly.



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Fig. Using special tool 8516 to depress valve for rocker arm removal-4.7L engine

To install:

  1. Rotate the crankshaft so that the piston of the cylinder to be serviced is at BDC.
  2.  
  3. Compress the valve spring and install each rocker arm in its original position.
  4.  
  5. Repeat for each rocker arm to be installed.
  6.  


WARNING
Be sure the rocker arms are installed with the concave pocket over the lash adjusters.

12-Valve Diesel
  1. Remove the valve cover(s).
  2.  
  3. Loosen the valve lash adjusting screw locknuts. Loosen the adjusting screws until they stop.
  4.  
  5. Remove the bolts from the rocker arm pedestals. Remove the pedestals and rocker arms.
  6.  
  7. Remove the retaining ring and push out the rocker arm shaft if further disassembly is desired.
  8.  
  9. Remove the pushrods. The rearmost pushrods are removed through the cowl panel access holes.
  10.  

To install:

  1. Make sure the dowel rings in the pedestals are installed in the dowel bores in the cylinder head.
  2.  
  3. If the pushrod is holding a pedestal off its seat, turn the engine until the pedestal reaches the seat.
  4.  
  5. Use clean engine oil to lubricate rocker arm components, cylinder head bolt threads and under bolt heads.
  6.  
  7. Install the bolts and tighten all 12mm bolts as follows:
    1. Tighten in the order shown, starting in the center of the head and working outward.
    2.  
    3. Tighten to 66 ft. lbs. (90 Nm) on the first step, then 89 ft. lbs. (120 Nm), then an additional 90º.
    4.  

  8.  



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Fig. Rocker arm assembly-12-valve diesel



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Fig. Rocker arm bolt tightening sequence-12-valve diesel

24-Valve Diesel
  1. Remove the cylinder head cover.
  2.  
  3. Unscrew and remove the rocker arm pedestal bolts.
  4.  
  5. Remove the pushrods. The rearmost pushrods are removed through the cowl panel access holes.
  6.  

To install:

  1. Be sure the pushrods are seated in the tappets.
  2.  
  3. Lubricate pushrod ends and other parts.
  4.  
  5. Tighten pedestal bolts to 27 ft. lbs. (36 Nm).
  6.  
  7. Adjust the valve lash.
  8.  



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Fig. Rocker arm and pedestal assembly-24-valve diesel

 
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