Camshaft R&R

This procedure covers removal and installation of the camshaft in a 1972 Ford F-100 with 302ci V8 engine, including timing chain removal, lifter extraction, and camshaft bearing inspection.

Warnings

Tools required

Parts

• Camshaft × 1 — Use OEM specification or performance camshaft per application
• Timing chain set (chain, gears, and tensioner) × 1 — Use OEM specification
• Camshaft bearings (if worn) × 1 — Use OEM specification
• Lifters (flat tappet or roller per application) × 16 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Oil pan gasket × 1 — Use OEM specification
• Front crankshaft seal × 1 — Use OEM specification
• Intake manifold gasket set × 1 — Use OEM specification
• Valve cover gaskets × 2 — Use OEM specification
• Pushrod guide plates (if equipped) × 2 — Use OEM specification
• Camshaft assembly lubricant × 1 — Moly-based cam lube
• Engine assembly lube × 1 — Use OEM specification
• RTV silicone sealant × 1 — High-temp silicone

Fluids

• 10W-30 or 10W-40 conventional engine oil — 5 qt
• Ethylene glycol green 50/50 coolant — 15 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect negative battery cable
3. Allow engine to cool completely (minimum 2 hours)
4. Remove hood for better access to engine compartment
5. Drain engine coolant into appropriate container
6. Drain engine oil and remove oil filter
7. Place reference marks on distributor housing and intake manifold for installation reference
8. Take photographs of vacuum line routing, ignition wire routing, and accessory positions

Procedure

1. 1

   Remove Upper Engine Components
   Remove air cleaner assembly. Disconnect throttle linkage, fuel line, and all vacuum hoses from carburetor. Remove distributor cap with spark plug wires attached and set aside. Remove distributor hold-down clamp and carefully pull distributor from engine, noting rotor position. Remove valve covers by removing 4 bolts per cover. Remove intake manifold: disconnect coolant hoses, remove carburetor if still attached, and remove intake manifold bolts. Lift intake manifold from engine.
2. 2

   Remove Rocker Arms and Pushrods
   Loosen rocker arm fulcrum bolts or nuts (16 total, one per valve) and rotate rocker arms to side. Note: many 302 heads use bolt-down fulcrum-style rockers (non-adjustable) rather than adjustable stud-mounted rockers with nuts; identify your configuration before proceeding. Remove pushrods (16 total) and place in order on a rack or label them for reinstallation in original positions. Inspect pushrod ends for wear. If reusing, pushrods must return to original locations.
3. 3

   Remove Front Engine Accessories and Radiator
   Remove radiator hoses (upper and lower). Remove fan shroud bolts and reposition shroud. Remove fan blade assembly (4 bolts). Remove alternator and brackets. Remove power steering pump and brackets if equipped, secure pump aside without disconnecting hoses. Remove water pump (5 bolts). Disconnect lower radiator support and remove radiator assembly for clearance.
4. 4

   Remove Harmonic Balancer and Timing Cover
   Remove harmonic balancer retaining bolt. Use harmonic balancer puller to remove balancer from crankshaft snout (never use impact or jaw-type puller on outer ring). Remove timing cover bolts (typically 5-6 bolts securing timing cover). Carefully pry timing cover from block, being careful not to damage mating surfaces. Remove and discard front crankshaft seal from timing cover.
5. 5

   Remove Timing Chain and Gears
   Rotate crankshaft until timing marks on cam gear and crank gear align (both marks should point toward each other). Remove camshaft gear retaining bolt. Remove camshaft gear and timing chain as an assembly by pulling forward. If gear is tight on cam, use two pry bars positioned opposite each other behind the gear to walk it off evenly. Remove crankshaft gear using gear puller if replacement is required. Verified detail (The stock 1972 Ford 302 uses a standard non-tensioned timing chain and gear set (no factory chain tensioner). A tensioner is not part of the OEM timing set for this engine, so listing/expecting a tensioner may mislead.): Note: the stock 302 timing set does not use a chain tensioner; only install a tensioner if a performance/aftermarket timing set specifically includes one.
6. 6

   Remove Oil Pan
   Raise and support vehicle on jack stands. Remove oil pan bolts (typically 14-16 bolts total around perimeter). If engine mounts allow, slightly raise engine approximately 1-2 inches using jack under oil pan with wood block for clearance. Lower oil pan and remove from vehicle. Clean all gasket material from block and pan mating surfaces.
7. 7

   Remove Lifters
   Using magnetic lifter removal tool, extract all 16 hydraulic lifters from their bores. Keep lifters in order using numbered container or rack. If lifters are stuck, rotate while pulling upward. Inspect lifter bores for scoring or damage. Mark each lifter with its cylinder and position (intake or exhaust) if reusing.
8. 8

   Remove Camshaft
   Thread camshaft installation handle into the threaded holes in the front of the camshaft (the sprocket bolt holes), or thread two long bolts into those holes to use as a handle. Carefully pull camshaft straight forward out of engine block, rotating slowly while pulling to clear cam bearings. Support camshaft weight along entire length to prevent bearing damage. Exercise extreme care not to nick or gouge cam bearings during removal. Once past bearings, inspect cam lobes for wear, scoring, or damage.
9. 9

   Inspect Camshaft Bearings and Block
   Inspect camshaft bearings in block for scoring, excessive wear, or damage. Check bearing-to-journal clearance specification (typically 0.001-0.003 inches). If bearings show wear, they must be replaced using bearing installation tool and driver set. Clean all oil passages in block using solvent and compressed air. Inspect thrust plate area on block for wear. Verify camshaft endplay specification will be maintained with new components.
10. 10

    Install New Camshaft
    Generously coat all camshaft lobes with camshaft assembly lubricant (moly-based). Coat all cam journals with engine assembly lube. Coat camshaft bearings in block with engine oil. Attach camshaft installation handle to new camshaft. Carefully insert camshaft into block, rotating slowly while pushing inward. Support entire length of camshaft to avoid bearing contact. Slide camshaft through all bearings until fully seated. Remove installation handle. Verify camshaft rotates freely by hand.
11. 11

    Install Timing Chain and Gears
    If removed, install crankshaft gear onto crankshaft with timing mark facing outward. Position timing chain onto camshaft gear. Align timing marks on both gears so they face each other when installed. Install camshaft gear and chain assembly onto camshaft, ensuring timing marks remain aligned (marks should be closest together when both point toward each other). Install the camshaft sprocket bolts (typically 3 bolts, with fuel pump eccentric if equipped) and tighten to specification. and tighten securely. Verify timing marks are correctly aligned. Install timing chain tensioner if equipped.
12. 12

    Install Lifters
    If reusing lifters, install each lifter in its original bore position. If installing new lifters with flat tappet camshaft, coat lifter faces with camshaft assembly lubricant. For roller lifters, coat with engine assembly lube. Insert each lifter into its bore, ensuring it slides freely. Rotate lifter while inserting to distribute lubricant. Verify all 16 lifters are fully seated in their bores.
13. 13

    Install Oil Pan
    Clean oil pan and block mating surfaces thoroughly. Apply thin bead of RTV silicone to front and rear main bearing cap junctions. Position new oil pan gasket on block or apply RTV per gasket manufacturer instructions. Lift oil pan into position, being careful not to disturb gasket. Install all oil pan bolts finger-tight, then tighten in spiral pattern from center outward. Lower engine onto mounts if raised. 9.0 lb-ft (12.0 Nm) in cross pattern.
14. 14

    Install Timing Cover and Front Components
    Install new front crankshaft seal into timing cover, ensuring seal lip faces inward. Apply thin bead of RTV silicone to timing cover gasket surfaces. Position new timing cover gasket and install timing cover onto block, aligning dowel pins. Install 7 timing cover bolts finger-tight, then torque to specification. Coat harmonic balancer hub with light oil. Install harmonic balancer onto crankshaft, ensuring key engages keyway. Install balancer retaining bolt and torque to specification. Install water pump with new gasket (5 bolts).
15. 15

    Install Pushrods and Rocker Arms
    Install each pushrod into its original position (or any position if new), ensuring lower end seats properly in lifter cup. Coat rocker arm ball sockets and valve stem tips with engine assembly lube. Position rocker arms over pushrods and valve stems. Install rocker arm nuts finger-tight. Rotate crankshaft to bring each cylinder to TDC compression stroke (both valves closed) before adjusting that cylinder's valves. For hydraulic lifters with adjustable stud-mounted rockers, tighten rocker arm nut until all lash is removed, then tighten an additional 1/4 to 3/4 turn to center the plunger. For 302 engines with non-adjustable bolt-fulcrum rockers, simply torque the fulcrum bolt to specification (approximately 17-23 ft-lbs) to establish correct preload.
16. 16

    Install Intake Manifold and Upper Components
    Clean intake manifold and cylinder head mating surfaces. Position new intake manifold gaskets on cylinder heads, ensuring port alignment and proper orientation. Apply thin bead of RTV silicone to front and rear block-to-head joints. Position intake manifold onto engine. Install all intake manifold bolts finger-tight. Torque intake manifold bolts to approximately 23-25 ft-lbs following the factory tightening sequence in two to three progressive stages. Reconnect all coolant hoses, vacuum lines, and throttle linkage. Install distributor, aligning rotor to original position and reference marks. Install distributor hold-down clamp. Install valve covers with new gaskets (4 bolts each). Install carburetor if removed.
17. 17

    Complete Reassembly
    Install alternator and brackets. Install power steering pump and brackets. Install fan blade assembly and shroud. Install radiator assembly and secure lower support. Connect radiator hoses. Install air cleaner assembly. Reconnect all electrical connections and vacuum lines per reference photographs. Install new oil filter. Reconnect battery negative cable. Install hood and adjust as necessary.
18. 18

    Fill Fluids and Initial Start
    Fill crankcase with 5 quarts of appropriate break-in oil (high-zinc 10W-30 or 10W-40 for flat tappet camshaft, or conventional oil for roller camshaft). Fill cooling system with approximately 13-15 quarts of 50/50 conventional green (IAT) ethylene glycol coolant mixture; verify exact capacity against factory specification. Prime oiling system by removing distributor and using priming tool in oil pump drive, rotating with drill until oil pressure shows on gauge. For flat tappet camshaft: Start engine and immediately bring to 2000-2500 RPM, varying speed between 2000-3000 RPM for 20-30 minutes to break in camshaft. Monitor oil pressure and temperature continuously. Do not allow engine to idle during break-in period.

Reassembly

1. Torque all fasteners to manufacturer specifications using proper sequence where applicable
2. Use new gaskets and seals throughout reassembly
3. Follow proper valve lash adjustment procedure for hydraulic lifters
4. Verify timing chain alignment before installing timing cover
5. Apply appropriate lubricants to all wear surfaces during assembly

Verification

• Verify engine oil pressure reaches normal range within seconds of starting
• Check for coolant, oil, and fuel leaks after initial start
• Verify ignition timing and adjust as necessary after break-in
• Listen for abnormal valve train noise (ticking should diminish as lifters pump up)
• Monitor engine temperature during break-in period
• After break-in and cool-down, recheck valve lash adjustment
• Change oil and filter after break-in period (500 miles for flat tappet, per manufacturer recommendation for roller)
• Road test vehicle and verify proper engine performance across RPM range

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