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    Ford Pick-ups and Broncos 1987-1996 Repair Guide

    Valve Lifters

    Print

    REMOVAL & INSTALLATION



    See Figures 1, 2, 3, 4, 5 and 6



    Click image to see an enlarged view

    Fig. Fig. 1: Remove the lifters from the 4.9L engine



    Click image to see an enlarged view

    Fig. Fig. 2: Remove the diesel engine lifters



    Click image to see an enlarged view

    Fig. Fig. 3: Exploded view of the hydraulic lifter used in all gasoline engines



    Click image to see an enlarged view

    Fig. Fig. 4: Remove the lifter from its bore-5.0L engine shown



    Click image to see an enlarged view

    Fig. Fig. 5: A magnet is useful in removing lifters from their bores



    Click image to see an enlarged view

    Fig. Fig. 6: Stuck lifters must be freed using a slide hammer type lifter removal tool

    4.9L Engine
    1. Disconnect the inlet hose at the crankcase filler cap.
    2.  
    3. Remove the throttle body inlet tubes.
    4.  
    5. Disconnect the accelerator cable at the throttle body. Remove the cable retracting spring. Remove the accelerator cable bracket from the upper intake manifold and position the cable and bracket out of the way.
    6.  
    7. Remove the fuel line from the fuel rail. Be careful not to kink the line.
    8.  
    9. Remove the upper intake manifold and throttle body assembly (see Fuel System ).
    10.  
    11. Remove the ignition coil and wires.
    12.  
    13. Remove the rocker arm cover.
    14.  
    15. Remove the spark plug wires.
    16.  
    17. Remove the distributor cap.
    18.  
    19. Remove the pushrod cover (engine side cover).
    20.  
    21. Loosen the rocker arm bolts until the pushrods can be removed. KEEP THE PUSHRODS IN ORDER, FOR INSTALLATION!
    22.  
    23. Using a magnetic lifter removal tool, remove the lifters. Wipe clean the exterior of each lifter as it's removed and mark it with an indelible marker, so that it can be installed in its original bore.
    24.  

    To install:
    1. Coat the bottom surface of each lifter with multi-purpose grease and coat the rest of the lifter with clean engine oil.
    2.  
    3. Install each lifter in its original bore using the magnetic tool.
    4.  
    5. Coat each end of each pushrod with multi-purpose grease and install each in its original position. Make sure that each pushrod is properly seated in the lifter socket.
    6.  
    7. Engage the rocker arms with the pushrods and tighten the rocker arm bolts enough to hold the pushrods in place.
    8.  
    9. Adjust the valve clearance.
    10.  
    11. Install the pushrod cover (engine side cover).
    12.  
    13. Install the distributor cap.
    14.  
    15. Install the spark plug wires.
    16.  
    17. Install the rocker arm cover.
    18.  
    19. Install the ignition coil and wires.
    20.  
    21. Install the upper intake manifold and throttle body assembly (see Fuel System ).
    22.  
    23. Install the fuel line at the fuel rail.
    24.  
    25. Install the accelerator cable bracket at the upper intake manifold. Install the cable retracting spring. Connect the accelerator cable at the throttle body.
    26.  
    27. Install the throttle body inlet tubes.
    28.  
    29. Connect the inlet hose at the crankcase filler cap.
    30.  

    5.0L and 5.8L Engines

    The 1993-96 5.0L engine uses roller lifters.

    1. Remove the intake manifold.
    2.  
    3. Disconnect the Thermactor® air supply hose at the pump.
    4.  
    5. Remove the rocker arm covers.
    6.  
    7. Loosen the rocker arm fulcrum bolts until the rocker arms can be rotated off the pushrods.
    8.  
    9. Remove the pushrods. KEEP THE PUSHRODS IN ORDER, FOR INSTALLATION!
    10.  
    11. Using a magnetic lifter removal tool, remove the lifters. Wipe clean the exterior of each lifter as it's removed and mark it with an indelible marker, so that it can be installed in its original bore.
    12.  

    To install:
    1. Coat the bottom surface of each lifter with multi-purpose grease and coat the rest of the lifter with clean engine oil.
    2.  
    3. Install each lifter in its original bore using the magnetic tool.
    4.  
    5. Coat each end of each pushrod with multi-purpose grease and install each in its original position. Make sure that each pushrod is properly seated in the lifter socket.
    6.  
    7. Engage the rocker arms with the pushrods and tighten the rocker arm fulcrum bolts to 18-25 ft. lbs. (24-34 Nm). No valve adjustment should be necessary, however, if there is any question as to post-assembly collapsed lifter clearance, see the "Valve Lash'' procedure in Routine Maintenance .
    8.  
    9. Install the rocker arm covers.
    10.  
    11. Connect the Thermactor® air supply hose at the pump.
    12.  
    13. Install the intake manifold.
    14.  

    7.5L Engine
    1. Remove the intake manifold.
    2.  
    3. Remove the rocker arm covers.
    4.  
    5. Loosen the rocker arm fulcrum bolts until the rocker arms can be rotated off the pushrods.
    6.  
    7. Remove the pushrods. KEEP THE PUSHRODS IN ORDER, FOR INSTALLATION!
    8.  
    9. Using a magnetic lifter removal tool, remove the lifters. Wipe clean the exterior of each lifter as it's removed and mark it with an indelible marker, so that it can be installed in its original bore.
    10.  

    To install:
    1. Coat the bottom surface of each lifter with multi-purpose grease and coat the rest of the lifter with clean engine oil.
    2.  
    3. Install each lifter in it original bore using the magnetic tool.
    4.  
    5. Coat each end of each pushrod with multi-purpose grease and install each in its original position. Make sure that each pushrod is properly seated in the lifter socket.
    6.  
    7. Rotate the crankshaft by hand until No. 1 piston is at TDC of compression. The firing order marks on the damper will be aligned at TDC with the timing pointer.
    8.  
    9. Engage the rocker arms with the pushrods and tighten the rocker arm fulcrum bolts to 18-25 ft. lbs. (24-34 Nm) in the following sequence:

      No. 1 intake and exhaust
       
      No. 3 intake
       
      No. 8 exhaust
       
      No. 7 intake
       
      No. 5 exhaust
       
      No. 8 intake
       
      No. 4 exhaust
       

    10.  

    1. Rotate the crankshaft on full turn - 360°- and re-align the TDC mark and pointer. Tighten the fulcrum bolt on the following valves:

      No. 2 intake and exhaust
       
      No. 4 intake
       
      No. 3 exhaust
       
      No. 5 intake
       
      No. 6 exhaust
       
      No. 6 intake
       
      No. 7 exhaust
       

    2.  

    1. Check the valve clearance as described under in Chapter 1 .
    2.  
    3. Install the intake manifold.
    4.  
    5. Install the rocker arm covers.
    6.  

    Diesel Engine
    1. Remove the intake manifold.
    2.  
    3. Remove the CDR tube and grommet from the valley pan.
    4.  
    5. Remove the valley pan strap from the front of the block.
    6.  
    7. Remove the valley pan drain plug and lift out the valley pan.
    8.  
    9. Remove the rocker arm covers.
    10.  
    11. Remove the rocker arms. KEEP THEM IN ORDER FOR INSTALLATION!
    12.  
    13. Remove the pushrods. KEEP THEM IN ORDER FOR INSTALLATION!
    14.  
    15. Remove the lifter guide retainer.
    16.  
    17. Using a magnetic lifter removal tool, remove the lifters. Wipe clean the exterior of each lifter as it's removed and mark it with an indelible marker, so that it can be installed in its original bore.
    18.  

    To install:
    1. Coat the bottom surface of each lifter with multi-purpose grease and coat the rest of the lifter with clean engine oil.
    2.  
    3. Install each lifter in it original bore using the magnetic tool.
    4.  
    5. Install the lifter guide retainer.
    6.  
    7. Install the pushrods, copper colored end up, into their original locations, making sure that they are firmly seated in the lifters.
    8.  
    9. Coat the valve stem tips with multi-purpose grease and install the rocker arms and posts in their original positions.
    10.  
    11. Turn the crankshaft by hand, until the timing mark is at the 11 o'clock position (viewed from the front).
    12.  
    13. Install all the rocker arm post bolts and tighten them to 20 ft. lbs. (27 Nm).
    14.  
    15. Install the rocker arm covers.
    16.  
    17. Clean all old RTV gasket material from the block and run a 1 / 8 in. (3mm) bead of new RTV gasket material at each end of the block. Within 15 minutes, install the valley pan. Install the pan drain plug.
    18.  
    19. Install the CDR tube, new grommet and new O-ring.
    20.  
    21. Install the intake manifold and related parts.
    22.  

    DISASSEMBLY AND ASSEMBLY



    Each lifter is an assembly of matched parts. When disassembling more than one lifter, keep the parts segregated. Mixing of parts between or among different lifters will result in improper operation of the lifter(s). Always mark the lifters so that you won't forget which bore from which they originally came. Lifters must be returned to their original bore. Always work on a clean work surface.

    1. Using needle-nosed pliers, remove the plunger lockring from the lifter. It may be necessary to depress the plunger.
    2.  
    3. Remove the pushrod cup, metering valve, plunger and spring from the lifter body.
    4.  
    5. Invert the plunger and remove the check valve retainer by prying up on it carefully. Remove the check valve (either a disc or ball) and the spring.
    6.  
    7. Clean all parts thoroughly and replace any damaged or worn parts.
    8.  

    To install:
    1. Place the plunger upside down on the clean work surface.
    2.  
    3. Place the check valve in position over the oil hole on the bottom of the plunger. Place the check valve spring on top of the check valve.
    4.  
    5. Place the check valve retainer over the check valve and spring. Push the retainer down, into place on the plunger.
    6.  
    7. Place the plunger spring and plunger, with the open end up, into the lifter body.
    8.  
    9. Place the metering valve in the plunger, followed by the pushrod cup.
    10.  
    11. Depress the plunger and install the lockring. Release the plunger and make sure the lockring stays in place with the spring pressure against it.
    12.  

    DIESEL HYDRAULIC VALVE LIFTER INSPECTION



    The lifters used on diesel engines require a special test fluid, kerosene is not satisfactory.

    Remove the lifters from their bores and remove any gum and varnish with safe solvent. Check the lifters for concave wear. If the bottom of the lifter is worn concave or flat, replace the lifter. Lifters are built with a convex bottom, flatness indicates wear. If a worn lifter is detected, carefully check the camshaft for wear.

    To test lifter leak down, submerge the lifter in a container of kerosene. Chuck a used pushrod or its equivalent into a drill press. Position the container of kerosene so the pushrod acts on the lifter plunger. Pump the lifter with the drill press until resistance increases. Pump several more times to bleed any air from the lifter. Apply very firm, constant pressure to the lifter and observe the rate which fluid bleeds out of the lifter. If the lifter bleeds down very quickly (less than 15 seconds), the lifter should be replaced. If the time exceeds 60 seconds, the lifter is sticking and should be cleaned or replaced. If the lifter is operating properly (leak down time 15-60 seconds) and not worn, lubricate and reinstall in engine.

    Always inspect the valve pushrods for wear, straightness and oil blockage. Damaged pushrods will cause erratic valve operation.

     
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