This procedure covers the removal and replacement of all rocker arms on the 3.5L V6 EcoBoost engine, requiring removal of both valve covers and related components.

Warnings

Tools required

Parts

• Rocker arms (set of 24) × 1 — Use OEM specification
• Valve cover gaskets (left and right) × 2 — Use OEM specification
• Valve cover bolt grommets × 1 — Use OEM specification
• Ignition coil O-rings × 6 — Use OEM specification
• PCV valve grommet × 1 — Use OEM specification

Fluids

• Motorcraft 0W-20 Full Synthetic — 1 qt

Preparation

1. Ensure engine is completely cool to the touch
2. Disconnect negative battery terminal and wait 10 minutes for SRS system to discharge
3. Remove engine cover by pulling upward on front tabs and lifting away
4. Relieve fuel system pressure by removing fuel pump fuse and cranking engine until it stalls
5. Place drain pan under vehicle and drain approximately 1 quart of coolant from radiator petcock to lower coolant level below intake manifold
6. Label and photograph all vacuum lines, harness connections, and ignition coil positions for reference during reassembly

Procedure

1. 1

   Remove ignition coils and spark plugs
   Disconnect all six ignition coil electrical connectors. Remove the bolt securing each ignition coil and pull coils straight up out of valve cover. Use spark plug socket to remove all six spark plugs from each bank. Keep plugs organized by cylinder for inspection.
2. 2

   Disconnect intake and accessory components
   Disconnect throttle body electrical connector and all intake air temperature sensors. Remove air intake tube from throttle body to air filter housing. Disconnect PCV hoses from both valve covers. Remove charge air cooler outlet pipe if it restricts access to right valve cover. Disconnect any vacuum lines attached to intake manifold.
3. 3

   Remove wiring harness from valve covers
   Locate all wiring harness retaining clips attached to valve cover studs and mounting points. Carefully unclip and route engine harness away from both valve covers to provide clear access. On some models, the fuel injector harness may need to be partially unclipped from the intake manifold.
4. 4

   Remove valve covers
   Remove all valve cover bolts in reverse of tightening sequence, starting from outside bolts and working inward. Gently pry valve covers loose using plastic pry tool at designated pry points. Lift covers straight up to clear ignition coil tubes. Remove old gaskets and clean all gasket surfaces thoroughly with parts cleaner and plastic scraper. Inspect valve cover mating surfaces for warping or damage.
   Torque spec

   Cover Bolts19 Nm (14 lb-ft)
5. 5

   Inspect and photograph camshaft timing marks
   Before removing any rocker arms, verify that engine is at TDC cylinder #1 or note current camshaft positions. Photograph timing chain position and camshaft alignment for reference. This ensures proper timing during reassembly. Check that all cam lobes are in proper position before proceeding.
6. 6

   Remove rocker arms from right bank (passenger side)
   Starting with cylinder 1, rotate crankshaft if necessary so camshaft lobe is pointing away from the rocker arm you are removing. This relieves spring pressure and allows safe removal. Remove rocker arm bolt while holding rocker arm to prevent it from springing up. Carefully lift rocker arm off valve stem and hydraulic lash adjuster. Place rocker arms in organized container marked by cylinder number and position (intake/exhaust). Repeat for all rocker arms on right bank.
   ⚠Always ensure camshaft lobe is pointing away from rocker arm before loosening bolt to prevent valve spring tension from launching components.
   Torque spec

   Rocker Arm Bolts30 Nm (22 lb-ft)
7. 7

   Remove rocker arms from left bank (driver side)
   Repeat the rocker arm removal process for the left cylinder bank. Ensure each camshaft lobe is pointing away from its corresponding rocker arm before removing the bolt. Keep all components organized by cylinder and position. Inspect each rocker arm for wear, scoring, or damage on the cam contact surface and valve stem contact pad.
   Torque spec

   Rocker Arm Bolts30 Nm (22 lb-ft)
8. 8

   Inspect hydraulic lash adjusters
   With rocker arms removed, inspect all hydraulic lash adjusters (HLAs) for proper seating in cylinder head. Check for leakdown by pressing down on each HLA with thumb - they should offer firm resistance. If any HLA compresses easily or feels spongy, it should be replaced. Remove and inspect HLAs if replacement is needed. Keep HLAs organized by position if reusing.
9. 9

   Clean and inspect components
   Thoroughly clean all rocker arm mounting surfaces on cylinder heads using parts cleaner and lint-free cloths. Inspect camshaft lobes for scoring, pitting, or excessive wear. Clean valve tips and check for mushrooming or damage. If reusing rocker arms, clean them thoroughly and inspect roller surface and pivot points for wear. Measure rocker arm bore diameter if specifications are available.
10. 10

    Install rocker arms on right bank
    Apply light coat of clean engine oil to rocker arm pivot points and roller surfaces. Ensure hydraulic lash adjusters are properly seated. Position each new or cleaned rocker arm over its corresponding valve stem and lash adjuster. CRITICAL: Rotate crankshaft so camshaft lobe is pointing AWAY from the rocker arm being installed. Install rocker arm bolt finger-tight first. Torque rocker arm bolt to specification only when cam lobe is in the base circle position (pointing away). Work through all rocker arms on right bank systematically.
    ⚠️Never torque rocker arm bolts when camshaft lobe is pressing on rocker arm - this will bend valves and cause catastrophic engine damage.
    Torque spec

    Rocker Arm Bolts30 Nm (22 lb-ft)
11. 11

    Install rocker arms on left bank
    Repeat rocker arm installation process for left cylinder bank. Apply clean engine oil to all contact surfaces. Ensure each camshaft lobe is pointing away from its rocker arm before torquing the bolt. Double-check that all 24 rocker arm bolts are properly torqued and that all rocker arms move freely on their pivots.
    Torque spec

    Rocker Arm Bolts30 Nm (22 lb-ft)
12. 12

    Verify valve train operation
    Manually rotate crankshaft two complete revolutions using socket on crankshaft bolt. Observe all rocker arms to ensure smooth operation without binding. Listen and feel for any abnormal resistance. Verify all rocker arms are making proper contact with valve stems and camshaft lobes. Check that timing marks still align correctly after rotation.
13. 13

    Install new valve cover gaskets and reinstall covers
    Install new valve cover gaskets into valve cover grooves, ensuring they are fully seated. Install new spark plug tube seals and grommets. Apply light coating of engine oil to gasket surfaces. Position valve covers carefully over ignition coil tubes and align with bolt holes. Install all valve cover bolts finger-tight first. Torque valve cover bolts in proper sequence from center outward to specification. Do not overtighten as this can distort covers and cause leaks.
    Torque spec

    Cover Bolts19 Nm (14 lb-ft)
14. 14

    Reinstall ignition coils and spark plugs
    Install spark plugs with anti-seize on threads and torque to specification (consult service manual for exact value, typically 15 Nm). Install new O-rings on ignition coils if provided. Insert ignition coils into valve cover tubes and secure with mounting bolts. Reconnect all ignition coil electrical connectors. Ensure coils are fully seated before tightening bolts.
15. 15

    Reconnect all components and refill fluids
    Reinstall charge air cooler outlet pipe if removed. Reconnect all PCV hoses, vacuum lines, and electrical connectors using reference photos. Reinstall air intake system and engine cover. Refill coolant system to proper level using Motorcraft Orange Coolant. Check engine oil level and add Motorcraft 0W-20 as needed to bring to full mark. Reconnect negative battery terminal.

Reassembly

1. Always install rocker arm bolts with camshaft lobe pointing away from rocker arm to prevent valve damage
2. Torque all valve cover bolts in proper sequence from center outward to prevent gasket distortion and oil leaks
3. Verify all electrical connectors are fully seated and locked - a partially connected coil connector will cause misfire codes
4. Double-check that PCV system is properly reconnected to prevent boost leaks and rough idle conditions

Verification

• Start engine and listen for any unusual valve train noise such as ticking or tapping - some initial noise is normal until lash adjusters pump up
• Check for oil leaks around valve cover perimeter after 5 minutes of operation
• Verify smooth idle with no misfires - use scan tool to check for pending codes
• Test drive vehicle and verify normal acceleration and boost performance
• Recheck valve cover bolt torque after first heat cycle (drive and cool down)
• Monitor oil consumption and check valve covers for leaks after 100 miles of operation

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