Section 03-01C: Engine, 7.5L MFI
1996 F-250, F-350, F-Super Duty Chassis Cab and Motorhome Workshop Manual
DISASSEMBLY AND ASSEMBLY

Subassemblies

 

Cylinder Head

SPECIAL SERVICE TOOL(S) REQUIRED
DescriptionTool Number
Valve Spring CompressorT70P-6049-A

Disassembly

  1. With cylinder head (6049) removed from engine (6007), remove rocker arm seat bolts, rocker arm seats (6A528) and rocker arms (6564). Remove left and right exhaust manifolds (9430) and spark plugs (12405).

  1. Clean carbon from combustion chambers before removing intake valves (6507) and exhaust valves (6505).

  1. Compress valve springs (6513)using Valve Spring Compressor T70P-6049-A. Remove valve spring retainer key (6518) and release valve springs. Remove valve spring retainers (6514), valve springs, valve stem seals (6571), and intake valves and exhaust valves. Discard valve stem seals.

  1. Clean and inspect cylinder head(s) and related components. Refer to Section 03-00.

  1. Refer to Section 03-00 for cylinder head and valve repair procedures.

Assembly

  1. NOTE: Lubricate all valve stems and valve guides with specified engine oil. Apply Ford Multi-Purpose Grease D0AZ-19584-AA or equivalent meeting Ford specification ESB-M1C93-B to the valve tips before installation.

    NOTE: Make sure the proper seal application for intake and exhaust are in place.

    Install each intake valve and exhaust valve in the port from which it was removed or to which it was fitted. Install new valve stem seal on each intake valve and exhaust valve.

  1. Set valve spring and valve spring retainer over valve stem. Compress valve spring and install valve spring retainer keys.

  1.  CAUTION: Reducing assembled height below specifications can cause spring breakage and rapid wear of camshaft lobe.

    With dividers, measure assembled height of valve spring from surface of spring pad on cylinder head to underside of valve spring retainer. Check dividers with accurate scale. If assembled height exceeds specification, install shim(s) below valve spring to reduce height to recommended dimension. Refer to Specifications in this section.





  1. Coat the rocker arm seats and sockets with Ford Multi-Purpose Grease D0AZ-19584-AA or equivalent meeting Ford specification ESB-M1C93-B. Make sure the rocker arm seat bolts are in a serviceable condition before installing them. Install rocker arms, rocker arm seats and rocker arm seat bolts. Refer to Rocker Arm in the In-Vehicle Service portion of this section.

  1. Install left and right exhaust manifolds and spark plugs.

 

Pistons, Piston Pins and Rings

SPECIAL SERVICE TOOL(S) REQUIRED
DescriptionTool Number
Piston Pin Remover/ReplacerT68P-6135-A

Disassembly

  1. Remove the connecting rod bearing (6211) from the connecting rod (6200) and connecting rod bearing cap.

  1. Mark the pistons (6108) to make sure they are assembled with same connecting rod and installed in the same cylinders from which they were removed.

  1. Using an arbor press and Piston Pin Remover/Replacer T68P-6135-A, press the piston pin (6135) from the piston and connecting rod. Remove the partial piston ring set (6148).

  1. Refer to Section 03-00 for cleaning and inspection procedures. Repair if required.



    Piston and Connecting Rod





    ItemPart NumberDescription
    1—Driver (Part of T68P-6135-A)
    2—Locator
    (Part of T68P-6135-A)
    3—Adapter
    (Part of T68P-6135-A)
    4—Cup (Part of T68P-6135-A)
    5—Pin Pusher
    (Part of T68P-6135-A)
    66135Piston Pin
    7—Receiving Tube
    (Part of T68P-6135-A)

Assembly

  1. NOTE: Check the fit of a new piston in the cylinder bore before assembling piston and piston pin to connecting rod. Piston pin bore of connecting rod and diameter of piston pin must be within specifications.

    Apply a light coat of specified engine oil to all parts. Assemble the piston to the connecting rod with the cylinder number side of the connecting rod and indentation notch in piston positioned as shown.





  1. Start the piston pin in the piston and the connecting rod. Using an arbor press, press the piston pin through the piston and connecting rod until the end of piston pin is 1.59-3.18mm (1/16-1/8 inch) below chamfer of the piston pin bore in the piston.

  1. Check the end gap of each ring in partial piston ring set. End gap must be within specifications. Follow the instructions contained on piston ring package and install the partial piston ring set.

  1. Check the ring-side clearance of compression rings with a feeler gauge inserted between the ring and the lower land. Feeler gauge should slide freely around the ring circumference without binding. Any wear will form a step at the inner portion of the lower land. If the lower lands have high steps, replace the piston.

  1. Make sure the connecting rod bearing and connecting rod bearing bore in the connecting rod and connecting rod bearing cap are clean. Foreign material under the connecting rod bearing will distort the connecting rod bearing and cause failure. Install connecting rod bearing in connecting rod and connecting rod bearing cap with tangs fitting in slots provided.

 

Valve Tappet, Hydraulic

 

Each valve tappet (6500) is a matched assembly. If parts of one are mixed with those of another, improper valve operation may result. Disassemble and assemble each valve tappet separately. Valve tappets should be tested after assembly. Refer to Section 03-00. Keep the valve tappets in proper sequence so they can be installed in their original bores.

Disassembly

  1. Grasp the lock ring with needlenose pliers to release it from the groove. It may be necessary to depress the plunger to fully release lock ring.

  1. Remove the push rod cup, metering valve disc and plunger assembly.

  1. Carefully remove the plunger spring, check valve spring, check valve retainer and check valve from the plunger.

  1. Refer to Section 03-00 for cleaning and inspection procedures.






    ItemPart NumberDescription
    1—Push Rod Cup (Part of 6500)
    2—Metering Valve Disc
    (Part of 6500)
    3—Check Valve (Part of 6500)
    4—Plunger Spring (Part of 6500)
    5—Body (Part of 6500)
    6—Check Valve Retainer
    (Part of 6500)
    7—Check Valve Spring
    (Part of 6500)
    8—Plunger (Part of 6500)
    9—Lock Ring (Part of 6500)

Assembly

  1. Place the plunger upside down on a clean work bench.

  1. Place the check valve (disc or ball check) in position over the oil hole on the bottom of the plunger. Set the check valve spring on top of the check valve (disc or ball check).

  1. Position the check valve retainer over the check valve and spring. Then, push the retainer down into place on the plunger.

  1. Place the plunger spring and the plunger (open end up) into tappet body.

  1. Position the metering valve disc in the plunger, and place push rod cup in the plunger.

  1. Depress the plunger and position the closed end of lock ring in the groove of the tappet body. With the plunger still depressed, position the open ends of lock ring in the groove. Release the plunger, and then depress it again to fully seat the lock ring.

  1. Use Hydraulic Tappet Leak-Down Tester TOOL-6500-E or equivalent to fill the valve tappet with test fluid. Refer to Section 03-00.

 

Cylinder Block Assembly

Disassembly

  1. Mount the engine on a work stand and remove all the parts not furnished with the new engine short block (6009).

  1. Remove the four cylinder head to block dowels (6A008) and the block drain plugs.

  1. Remove the old engine short block assembly from the work stand.

Assembly

  1. Clean the gasket and seal surfaces of all serviceable parts and assemblies.

  1. Position the new engine short block assembly on a work stand and install the cylinder head to block dowels and block drain plugs.

  1. Transfer all serviceable parts removed from the old engine short block.

  1. Check all assembly clearances. Refer to Specifications in this section. Correct as necessary.

 

Cylinder Block, Bare

Before replacing a cylinder block (6010), determine if it is repairable. If so, make the necessary repairs. Refer to Section 03-00.

Disassembly

  1. Mount the old engine in a work stand and completely disassemble.

  1. Make sure that cylinder bores are ridge-reamed before removing piston and connecting rod, if required.

  1. Remove the cylinder head to block dowels and the block drain plugs.

Assembly

  1. Clean the gasket and seal surfaces of all serviceable parts and assemblies.

  1. Position the new cylinder block in a work stand and install the cylinder head to block dowels and the block drain plugs.

  1. Transfer all serviceable parts removed from the old cylinder block.

  1. Check all assembly clearances. Refer to Specifications in this section. Correct as necessary.