Complete replacement of all rocker arms on both banks of the 3.5L EcoBoost V6 engine, including removal of valve covers, timing components, and camshafts.

Warnings

Tools required

Parts

• Rocker arms (24 total) × 24 — Use OEM specification
• Valve cover gaskets (left and right) × 2 — Use OEM specification
• Valve cover bolt grommets × 24 — Use OEM specification
• Camshaft cap bolts × 32 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Timing chain tensioner gaskets × 2 — Use OEM specification
• VVT solenoid O-rings × 4 — Use OEM specification

Fluids

• Motorcraft 5W-20 Synthetic Blend engine oil — 6 qt

Preparation

1. Disconnect negative battery cable and wait 10 minutes for capacitive discharge
2. Remove engine cover by pulling upward on retaining clips
3. Drain engine oil completely and reinstall drain plug
4. Remove air intake system including air filter housing and intake tubes
5. Disconnect ignition coils and remove all spark plugs, labeling by cylinder position
6. Remove accessory drive belt
7. Position vehicle safely on level ground with parking brake engaged

Procedure

1. 1

   Remove valve covers
   Disconnect all electrical connectors from valve covers including VVT solenoids and camshaft position sensors. Remove PCV hoses and breather tubes. Remove valve cover bolts in reverse of tightening sequence (outside to inside pattern). Carefully lift valve covers straight up to avoid damaging gasket surfaces.
2. 2

   Set engine to TDC cylinder 1
   Rotate crankshaft clockwise using a socket on the harmonic balancer bolt until cylinder 1 is at top dead center on compression stroke. Verify timing marks on both camshafts align with their respective marks on the cylinder head. Install camshaft alignment timing tools to lock camshafts in position.
   ⚠Only rotate engine in normal direction of rotation (clockwise from front). Never rotate backwards.
3. 3

   Remove timing drive components
   Remove front engine cover mounting bolts and carefully remove timing cover. Remove timing chain tensioners by releasing pawl and slowly allowing tensioner to collapse. Remove timing chain guides. Mark timing chain orientation to camshaft and crankshaft sprockets with paint marker before removal. Remove timing chains from both banks.
   ⚠Timing chain tensioners are under spring pressure. Control release carefully to prevent injury.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
4. 4

   Remove camshaft position sensors and VVT solenoids
   Disconnect electrical connectors from all camshaft position sensors (4 total). Remove sensor mounting bolts and carefully extract sensors. Remove VVT solenoid mounting bolts and remove solenoids from front of camshafts. Inspect O-rings and replace during reassembly.
   Torque spec

   Sensor Bolts12 Nm (9 lb-ft)
5. 5

   Remove right bank camshaft caps and camshafts
   With camshafts locked in position, loosen camshaft cap bolts in sequence from outside to inside, in multiple passes (1/4 turn each pass) to release valve spring tension evenly. Remove all camshaft caps and place in order on clean workspace. Carefully lift both intake and exhaust camshafts from right cylinder head. Keep camshaft caps with their respective camshafts.
   ⚠Camshaft caps must be loosened gradually and evenly. Sudden release can damage caps, camshafts, or cylinder head.
6. 6

   Remove right bank rocker arms
   Remove all 12 rocker arms from right cylinder head, keeping them in exact order (cylinders 1-2-3 intake/exhaust). Place rocker arms in numbered compartments or label clearly. Inspect cam follower surfaces for scoring, pitting, or excessive wear. Remove and inspect hydraulic lash adjusters from each rocker arm bore.
7. 7

   Remove left bank camshaft caps and camshafts
   Repeat camshaft cap removal procedure for left bank. Loosen camshaft cap bolts in sequence from outside to inside, in multiple passes to release valve spring tension evenly. Remove all camshaft caps maintaining organization. Carefully lift both intake and exhaust camshafts from left cylinder head.
   ⚠Camshaft caps are not interchangeable between positions or banks. Maintain strict organization.
8. 8

   Remove left bank rocker arms
   Remove all 12 rocker arms from left cylinder head (cylinders 4-5-6 intake/exhaust), maintaining exact order and position. Inspect cam follower surfaces and hydraulic lash adjusters. Clean all rocker arm bores in cylinder heads with brake cleaner and compressed air.
9. 9

   Clean and inspect surfaces
   Thoroughly clean all camshaft journals in cylinder heads using brake cleaner. Inspect camshaft bearing surfaces for scoring or damage. Clean valve cover mating surfaces on cylinder heads using plastic gasket scraper. Ensure all oil passages are clear. Inspect camshaft lobes for wear or damage.
10. 10

    Install new rocker arms on left bank
    Lubricate new hydraulic lash adjusters with clean engine oil and install in cylinder head bores. Lubricate new rocker arms with clean engine oil. Install all 12 rocker arms for left bank (cylinders 4-5-6) in correct positions. Ensure each hydraulic lash adjuster is properly seated in its bore and rocker arm.
11. 11

    Install left bank camshafts
    Lubricate all camshaft journals and lobes with clean engine oil. Carefully install exhaust and intake camshafts into left cylinder head, ensuring timing alignment marks are correctly positioned. Install camshaft caps in exact original positions (caps are numbered and directional). Install new camshaft cap bolts hand-tight initially.
12. 12

    Torque left bank rocker arms
    Working one rocker arm at a time, rotate the corresponding camshaft so the lobe points away from the rocker arm (base circle). Tighten the rocker arm bolt to specification. Repeat for all 12 rocker arms on left bank, ensuring each cam lobe is on base circle during tightening. Tighten camshaft cap bolts in sequence from center outward in 3 passes to final torque.
    ⚠️Each rocker arm bolt MUST be tightened only when its camshaft lobe is on base circle (pointing away). Tightening on the lobe will damage valvetrain components.
    Torque spec

    Rocker Arm Bolts30 Nm (22 lb-ft)

    Gasket Bolts23 Nm (17 lb-ft)
13. 13

    Install new rocker arms on right bank
    Lubricate new hydraulic lash adjusters and rocker arms with clean engine oil. Install all components for right bank (cylinders 1-2-3) in correct positions. Ensure proper seating of all hydraulic lash adjusters.
14. 14

    Install right bank camshafts and torque rocker arms
    Lubricate and install right bank camshafts with timing marks correctly aligned. Install camshaft caps in original positions with new bolts hand-tight. Working one rocker arm at a time, rotate camshaft to base circle position and torque rocker arm bolt to specification. Repeat for all 12 rocker arms. Tighten camshaft cap bolts in sequence from center outward to final torque.
    Torque spec

    Rocker Arm Bolts30 Nm (22 lb-ft)

    Gasket Bolts23 Nm (17 lb-ft)
15. 15

    Reinstall timing components
    Install timing chains onto camshaft and crankshaft sprockets ensuring all timing marks align with paint marks made during disassembly. Install timing chain guides. Install new timing chain tensioner gaskets and install tensioners (compressed and locked). Release tensioner pawls to apply proper chain tension. Verify all timing marks are correctly aligned. Install new timing cover gasket and reinstall timing cover.
    ⚠️Verify timing alignment at least three times before proceeding. Incorrect timing will destroy the engine.
    Torque spec

    Cover Bolts19 Nm (14 lb-ft)

    Mounting Bolts31 Nm (23 lb-ft)
16. 16

    Reinstall sensors and VVT solenoids
    Install new O-rings on VVT solenoids lubricated with clean engine oil. Install VVT solenoids to front of camshafts. Install camshaft position sensors with new mounting bolts. Reconnect all electrical connectors.
    Torque spec

    Sensor Bolts12 Nm (9 lb-ft)
17. 17

    Reinstall valve covers
    Install new valve cover gaskets and bolt grommets. Position valve covers on cylinder heads ensuring gaskets are properly seated. Install valve cover bolts and tighten in sequence (inside to outside pattern) to specification. Reconnect PCV hoses, breather tubes, and all electrical connectors.
    Torque spec

    Cover Bolts19 Nm (14 lb-ft)

Reassembly

1. Install spark plugs and reconnect ignition coils to correct cylinders
2. Reinstall accessory drive belt ensuring proper routing and tension
3. Reinstall air intake system and engine cover
4. Fill engine with 6 quarts of Motorcraft 5W-20 synthetic blend engine oil
5. Reconnect negative battery cable

Verification

• Before starting engine, manually rotate crankshaft two complete revolutions and verify all timing marks return to correct alignment
• Check for any binding or unusual resistance when rotating crankshaft
• Start engine and listen for unusual valvetrain noise (ticking, knocking, or rattling)
• Allow engine to idle for 5 minutes and verify no oil leaks from valve covers or timing cover
• Check for proper oil pressure on instrument cluster
• Verify no diagnostic trouble codes related to camshaft position or timing
• Road test vehicle under light load and verify smooth operation across RPM range

More procedures for this vehicle