M11 Series – Service Manual – 003-009   Rocker Lever Assembly

• Remove the air piping from the intake manifold.
• Remove the rocker lever cover. Refer to Procedure 003-011.
• Remove the engine brakes, if equipped. Refer to Procedure 020-001.
• Remove the push rods and push tubes. Refer to Procedure004-014.

NOTE: This action applies only to engines built with the cast iron supports.

Install a piece of 1/4-inch key stock 457-mm [18-in] long on top of the four front rocker lever assembly supports. Use four M10 – 1.50 x 25 flange head capscrews to secure the bar stock to the supports.

The capscrews on the two end supports will fasten to the engine brake mounting holes on one side of the bar stock. The capscrews on the two center supports will fasten to the engine brake mounting holes on the opposite side of the bar stock.

Loosen, but do not remove, the eight rocker shaft capscrews. The capscrews hold the rocker lever assemblies together.

On engines with the cast-iron supports, grasp hold of the bar stock and lift the front rocker lever assembly from the engine. Do not lift the assemblies by grasping the rocker levers and shaft. The shaft and levers can lift out of the supports allowing the levers to slide off the shaft.

On engines with the aluminum supports, grasp hold of the assembly by the rocker levers and shaft, and lift them from the engine.

Repeat the process to remove the rear rocker lever assembly.

Mark each rocker lever, shaft and support with their relative position in the engine.

The rocker lever assemblies must be installed in the same position they were removed from.

Cast Iron Supports

Remove the rocker shaft capscrews (1) and retaining blocks (2). Lift the shaft and levers out of the supports (3).

Remove the rocker levers (4) from both shaft assemblies.

Aluminum Supports

Remove the rocker shaft capscrews (1) and end supports (2).

Remove the rocker levers (3) and middle supports (4) from both shaft assemblies.

Remove the locknuts and the adjusting screws from each rocker lever.

WARNING  When using a steam cleaner, wear safety glasses or a face shield, as well as protective clothing. Hot steam can cause serious personal injury.

Use steam or solvent to clean the parts. Dry with compressed air.

Be sure to blow out the oil passages.

Inspect the rocker levers for cracks, excessive pitting, or unusual wear.

Use the Overhead Reuse Guidelines, Bulletin Number 3810388, to identify wear patterns and excessive wear.

Inspect rocker levers for cracks. Inspect sockets and crossheads for roughness and unusual wear. Polishing of the socket and crosshead is considered normal wear.

Inspect the adjusting screws and locknuts for damaged threads.

Inspect the adjusting screw threads in the rocker levers for damaged threads.

Inspect the rocker levers for loose rivets.

Inspect the adjusting screws for wear on the ball end.

Measure each rocker lever bushing bore inside diameter.

Inspect the rocker lever shafts for pitting, scoring, or other damage.

Measure each rocker lever shaft outside diameter.

Use Bulletin Number 3810388, the Overhead Reuse Guidelines to identify wear patterns and excessive wear.

If worn or damaged parts are found, or the rocker lever bushings or shafts are not within the specifications given, the rocker lever assemblies must be rebuilt.

Inspect the sockets in the injector rocker levers for wear or damage.

Inspect the valve rocker lever pads for wear, cracks, or other damage.

If wear, cracks, or other damage is found, the rocker lever must be replaced.

Use crack detection kit, Part Number 3375432, to inspect the rocker lever supports for cracks or damage.

Use crack detection cleaner, Part Number 3375433, to clean the rocker levers and shaft supports. Dry with compressed air.

Use crack detection penetrant, Part Number 3375435, to spray the rocker levers and shaft supports.

NOTE: Do not dry with compressed air.

Allow the penetrant to dry for 15 minutes.

Remove the excess penetrant with a dry cloth.

Use crack detection developer, Part Number 3375434, to spray the rocker levers and shaft supports.

Inspect the levers and supports.

Cracks will appear as a solid, bright line.

Cavitation in the casting will appear as a small round mark.

If cracks or cavitation are found, the part must be replaced.

Sockets do not need to be removed for inspection. In case the socket is inadvertently removed, install the socket by pressing it into the clip at an angle.

WARNING  If rivets are missing from either end of the rocker levers, you must remove the oil pan to check for rivets stuck to the bottom of the pan.

A self-tapping screw, Part Number 3099292, was released March 3, 1998, for field repairs only on missing rocker lever rivets.

If rivets are found in the oil pan or are missing from either end of the rocker levers, replace the missing rivets with self-tapping screws, and check the remaining rivets for tightness. Check for tightness by using a fingernail or a screwdriver. If rivets are tight, do not remove them.

The recommended installation includes the use of a lubricant on the screw (2) as it is installed into the rocker lever (1). The screw (2) must be tightened with a T20 Torx bit.

Cast Iron Supports

CAUTION  Make sure the rocker lever shafts are installed with the arrow on the end of the shafts pointed DOWN. When the arrow points up, cross drillings to the rocker levers are oriented differently which has an adverse affect to rocker lever oiling.

The rocker lever shafts are labeled front and rear on the end of the shafts (1). The arrows on the shafts (2) must be pointed downward to make sure an oil flows to the rocker levers.

The shaft end supports are not interchangeable.

Use clean 15W-40 oil to lubricate both shafts.

Install the front end support on each shaft.

Install the retaining blocks, washers and capscrews through the end supports.

Install the rocker levers in the correct sequence as shown.

NOTE: The rocker levers must be installed so they will be in the same position in the engine as when they were removed.

Install one of the two shaft center supports on the shaft.

Install the retaining block, washer and capscrew through the center support.

Install the remaining levers and supports with the intake (l) and exhaust (E) valve levers in the correct position as shown.

Install the remaining retaining blocks, washers and capscrews.

Install the key stock used to remove the rocker levers on top of the supports.

Aluminum Supports

CAUTION  Make sure the rocker lever shafts are installed with the arrow on the end of the shafts pointed DOWN. When the arrow points up, cross drillings to the rocker levers are oriented differently which has an adverse affect to rocker lever oiling.

The rocker lever shafts are labeled front and rear on the end of the shafts (5). The shaft end supports have arrows (6) stamped on them to align with arrows (7) stamped on the ends of both rocker lever shafts. The arrows on the shafts and the shaft end support must be aligned to be installed correctly. The shaft end supports are not interchangeable.

Use clean 15W-40 oil to lubricate both shafts.

Install the front end support on each shaft.

Install the washers and capscrews through the end supports.

Install the rocker levers in the correct sequence as shown.

NOTE: The rocker levers must be installed so they will be in the same position in the engine as when they were removed.

Install one of the two shaft center supports on the shaft.

Install the capscrew and washer through the center support.

Install the remaining levers and supports with the intake (I) and exhaust (E) valve levers in the correct position as shown.

Install the remaining capscrews and washers.

The rocker lever assemblies must be installed in the engine so they are in same position as they were removed from.

Install the assemblies on the engine.

Hand tighten the mounting capscrews at this time. The rocker lever side clearance must be adjusted before the capscrews are tightened to their final torque value.

Push or use a hammer to tap the number five rocker lever support toward the front of the engine.

Tighten the mounting capscrews at this time.

Install a 0.50 mm [0.020 inch] feeler gauge between the number five support and the intake lever for the number four cylinder.

Push or use a hammer to tap the number six support toward the front of the engine.

Tighten the mounting capscrews.

Install a 0.50 mm [0.020 inch] feeler gauge between the number six support and the exhaust lever for the number five cylinder.

Push or use a hammer to tap the number seven support toward the front of the engine.

Tighten the mounting capscrews.

Install a 0.5 mm [0.020 inch] feeler gauge between the number seven support and the intake lever for the number six cylinder.

Push or use a hammer to tap the number eight support toward the front of the.

Tighten the Number 5, 6, 7, and 8 support capscrews to their final torque.

Push or use a hammer to tap the number four support toward the rear of the engine.

Tighten the mounting capscrews.

Install a 0.50 mm [0.020 inch] feeler gauge between the number four support and the intake lever for the number three cylinder.

Push or use a hammer to tap the number three support toward the rear of the engine.

Tighten the mounting capscrews.

Install a 0.50 mm [0.020 inch] feeler gauge between the number three support and the exhaust lever for the number two cylinder.

Push or use a hammer to tap the number two support toward the rear of the engine.

Tighten the mounting capscrews.

Install a 0.50 mm [0.020 inch] feeler gauge between the number two support and the intake lever for the number one cylinder.

Push or use a hammer to tap the number one support toward the rear of the engine.

Tighten the Number 1, 2, 3, and 4 support capscrews to their final torque.

Check the front and rear assemblies for correct clearance. Check the support capscrews for the correct torque value.

• Install the push rods and push tubes. Refer to Procedure 004-014.
• Install the engine brakes, if applicable. Refer to Procedure 020-001.
• Adjust the valves and injectors. Refer to Procedure 003-004.
• Install the rocker lever cover. Refer to Procedure 003-011.
• Install the air piping to the intake manifold. Use the manufacturer’s specifications for the correct torque value.