Cylinder Head R&R

Complete removal and reinstallation of both cylinder heads on the 302ci V8, including disassembly of valve train, intake/exhaust manifolds, and related components.

Warnings

Tools required

Parts

• Cylinder head gasket set × 1 — Use OEM specification
• Intake manifold gasket set × 1 — Use OEM specification
• Exhaust manifold gaskets × 2 — Use OEM specification
• Valve cover gaskets × 2 — Use OEM specification
• Pushrod guide plate gaskets × 2 — Use OEM specification
• Head bolt set × 1 — Use OEM specification
• Intake manifold bolt set × 1 — Use OEM specification
• Exhaust manifold bolt set × 1 — Use OEM specification
• Valve stem seals × 16 — Use OEM specification

Fluids

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

Preparation

1. Disconnect negative battery cable and secure away from battery post
2. Drain engine coolant completely into appropriate container
3. Drain engine oil and remove oil filter
4. Remove air cleaner assembly and label all vacuum hoses for reinstallation
5. Tag and photograph all electrical connections, fuel lines, and linkages before disconnection
6. Support front of vehicle on jack stands if additional clearance is needed

Procedure

1. 1

   Remove valve covers and accessories
   Remove both valve covers by removing the 6 bolts per cover. Remove alternator, power steering pump (if equipped), and A/C compressor (if equipped) - leave hoses attached and secure components aside. Remove ignition coil and spark plug wires, labeling wire positions.
2. 2

   Remove intake manifold
   Disconnect throttle linkage, fuel line, and all vacuum lines from carburetor and intake manifold. Remove carburetor and spacer. Remove the 12 intake manifold bolts working from the ends toward the center. Carefully lift intake manifold straight up to avoid damaging gasket surfaces. Remove and discard intake manifold gaskets and end seals.
3. 3

   Remove exhaust manifolds
   Disconnect exhaust pipes from both exhaust manifolds at the flange connection. Remove the 8 exhaust manifold bolts per side. Remove exhaust manifolds and discard gaskets. Inspect manifolds for cracks or warpage.
4. 4

   Remove rocker arms and pushrods
   Loosen each rocker arm fulcrum bolt and remove rocker arms. Keep rocker arms in order or mark them for reinstallation in original positions. Remove all 16 pushrods and store them in order. Inspect pushrods for wear or bending by rolling on flat surface.
5. 5

   Remove cylinder head bolts - driver side
   Remove the 14 cylinder head bolts from the driver side head in reverse order of installation sequence (outside bolts first, working toward center). Use breaker bar if necessary but do not apply excessive force to avoid bolt breakage. Keep bolts in order for inspection. in reverse order of installation sequence (outside bolts first, working toward center). Use breaker bar if necessary but do not apply excessive force to avoid bolt breakage. Keep bolts in order for inspection. Verified detail (The Ford 302 (small-block Windsor) uses 10 cylinder head bolts per head, not 13. This is a well-established fact for the 289/302/351W family.): Remove the 10 cylinder head bolts from the driver side head in reverse order of installation sequence (outside bolts first, working toward center).
6. 6

   Remove driver side cylinder head
   With all bolts removed, carefully lift driver side cylinder head straight up off the block. If head is stuck, tap gently with soft mallet on a corner boss - never pry between mating surfaces. Place head on wood blocks with combustion chambers facing up.
7. 7

   Remove cylinder head bolts - passenger side
   Remove the 14 cylinder head bolts from the passenger side head in reverse order of installation sequence. Keep bolts in order for inspection. in reverse order of installation sequence. Keep bolts in order for inspection. Verified detail (The Ford 302 uses 10 head bolts per head, not 13.): Remove the 10 cylinder head bolts from the passenger side head in reverse order of installation sequence.
8. 8

   Remove passenger side cylinder head
   Carefully lift passenger side cylinder head straight up off the block. Place head on wood blocks with combustion chambers facing up. Remove and discard head gaskets from block.
9. 9

   Clean and inspect block deck surfaces
   Thoroughly clean both block deck surfaces using gasket scraper, taking care not to gouge the cast iron surfaces. Remove all old gasket material and carbon deposits. Clean all coolant and oil passages. Inspect block deck for warpage using straightedge and feeler gauge - maximum allowable warpage is 0.003 inches per 6 inches of length. Check for cracks around coolant passages and bolt holes.
10. 10

    Inspect and service cylinder heads
    Clean cylinder head mating surfaces completely. Inspect heads for cracks, especially between valve seats and in exhaust ports. Check head flatness with straightedge - maximum allowable warpage is 0.006 inches total length. If heads require machining, do not remove more than 0.010 inches of material. Clean all bolt holes in heads with thread chaser or tap.
11. 11

    Install driver side cylinder head
    Position new head gasket on block with orientation markings (UP or FRONT) correctly positioned. Carefully lower driver side cylinder head onto block, aligning dowel pins. Install all 14 head bolts finger-tight. Torque head bolts in proper sequence (center bolts first, working outward in spiral pattern) to 65 ft-lb in first pass, then to final torque of 70-72 ft-lb in second pass. Verified detail (302 has 10 head bolts per head, not 13. Ford factory spec for the 302 head bolts is a three-step sequence with final torque of 65-72 ft-lb, NOT 85 ft-lb. The 85 ft-lb figure is incorrect and could over-stress the bolts/threads.): Install all 10 head bolts finger-tight. Torque head bolts in proper sequence (center bolts first, working outward in spiral pattern) to 55 ft-lb in first pass, then 65 ft-lb in second pass, then final torque of 65-72 ft-lb - verify for your specific application.
12. 12

    Install passenger side cylinder head
    Position new head gasket on block with orientation markings correctly positioned. Carefully lower passenger side cylinder head onto block, aligning dowel pins. Install all 10 head bolts finger-tight. Torque head bolts in proper sequence to 55 ft-lb in first pass, then 65 ft-lb in second pass, then final torque of 65-72 ft-lb. Verified detail (The 1972 Ford 302 V8 uses 14 head bolts per cylinder head, not 13.): Install all 14 head bolts finger-tight. Verified detail (Same torque specification concern as step 11. The typical 1972 Ford 302 final torque is 70-72 ft-lb, not 75 ft-lb.): Torque head bolts in proper sequence to 65 ft-lb in first pass, then to final torque of 70-72 ft-lb in second pass.
13. 13

    Install pushrods and rocker arms
    Install all 16 pushrods in their original positions, ensuring each pushrod seats fully in its lifter socket - rotate engine by hand if necessary to verify seating. Install rocker arms with fulcrum seats and bolts. Torque rocker arm fulcrum bolts to 17-23 ft-lb. Verified detail (The 1972 302 typically uses non-adjustable, positive-stop rocker arm bolts torqued to approximately 17-23 ft-lb (Ford spec ~18-22 ft-lb). The stated range is close but should be verified against Ford spec; also many early 302s used adjustable rockers requiring lash setting.): Adjust valve lash if using adjustable rockers, or torque rocker arm fulcrum bolts to 17-23 ft-lb if using non-adjustable positive-stop design with fulcrum seats.
14. 14

    Install exhaust manifolds
    Position new exhaust manifold gaskets on cylinder heads. Install exhaust manifolds and start all 8 bolts per side finger-tight. Torque exhaust manifold bolts to 18-24 ft-lb working from center bolts outward. Reconnect exhaust pipes to manifold flanges.
15. 15

    Install intake manifold
    Apply thin bead of RTV silicone to block end rails where intake manifold seats. Position new intake manifold gaskets on cylinder heads. Apply small dab of RTV at corners where end rails meet gaskets. Carefully lower intake manifold into position. Install all 12 intake manifold bolts finger-tight. Torque intake manifold bolts in proper sequence (center bolts first, working outward) in progressive steps to a final value of 23-25 ft-lb. Allow RTV to cure for 15 minutes before adding coolant.
16. 16

    Reinstall accessories and valve covers
    Reinstall carburetor with new gasket. Reconnect throttle linkage, fuel line, and all vacuum lines per original tags and photos. Reinstall ignition coil and spark plug wires in correct positions. Install new valve cover gaskets and reinstall valve covers, torquing bolts to 3-5 ft-lb. Reinstall alternator, power steering pump, and A/C compressor.
17. 17

    Refill fluids and bleed cooling system
    Install new oil filter and refill engine with 5 quarts of 10W-30 or 10W-40 conventional oil. Close cooling system drains and refill with 15 quarts of ethylene glycol green 50/50 coolant. Leave radiator cap off. Start engine and allow to warm to operating temperature while monitoring for leaks. Add coolant as air bleeds from system. Install radiator cap when system is full and engine reaches operating temperature.

Reassembly

1. Torque all fasteners in multiple progressive steps as specified, never in single step to final value
2. Use new gaskets for all removed components - do not reuse old gaskets
3. Apply anti-seize compound to spark plug threads but not to head bolts unless specified
4. Verify all electrical connections are secure and routing matches original configuration

Verification

• Start engine and verify oil pressure builds immediately on oil pressure gauge
• Check for coolant, oil, and exhaust leaks at all removed components
• Listen for unusual valve train noise - ticking or tapping may indicate incorrect pushrod installation or valve lash adjustment
• Verify engine reaches normal operating temperature and cooling fan cycles properly
• Road test vehicle and verify normal power delivery and smooth operation through RPM range
• Recheck cylinder head bolt torque after engine reaches operating temperature and cools (recommended after 500 miles)

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