Rocker Arm Removal - BIG PROBLEM

Hello again folks,

Having sucessfully removed 11 rocker-arms last night, I've got a problem with the
last one.

This rocker arm is located on the inlet side of the left hand camshaft. Its at the end closest to the crank-pulley.

After several attempts at removal, which included lots of sweat, a broken 5mm hex wrench, and some blood, I still can't get the damn thing off!

To make matters worse, the interior of the shaft where the hex key fits has become rounded off - I stopped working on it as soon as I noticed this, but its still damaged...

So... has anyone got any ideas how to get the arm off?

Here are my ideas so far:

1) Attach a new 5mm hex wrench to the bolt with a good adhesive. When the bolt comes out I can replace it with a new one.

2) Attack the 8mm nut at the other end of the shaft, although access is very limited, and the manual advises you undo the 5mm end, not the 8mm nut end!

3) Attempt to file the insides of the hex bolt, and then press a 5.5mm or 6mm hex key in place and attempt to turn that.

4) Remove the entire head (with camshaft!) and take it to a machine shop where they can possibly drill out the rocker arm shaft without damaging anything else!

Thanks once again,

- roGER

Option #4 is quite safe, but also quite spendy. I don't think you need to go there.

#3 is certainly thinkable. The 5.5mm hex key may nearly fit into a rounded 5mm fastener. Filing would be tricky, if necessary.

#2 sounds scary. Perhaps this woudl be a mistake. Sounds difficult to reach too.

#1 sounds intriguing. I'd be HAPPY to ruin a 5mm tool and fastener for the joy and relief of solving the problem with the engine in the car! Use excellent glue and patience while it dries completely. Perhaps epoxy.

Also, it is a good idea to TIGHTEN frozen fasteners slightly before backing them out. Heat is a very popular tool. If you got it REALLY HOT (the thing that the fastener is screwed into) it might come right out.

Let us know how this ends. I think you will get it out without having to invoke option #4.



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'83 SC

Thanks very much for the advice - I too know the value of tightening something just to disturb it a bit before attempting to untighten it.

Anyway the solution was.....

None of the above!

Went to Sears last night and bought the following:

1 x 3/8 drive 5mm hex SOCKET (not key)

1 x 3/8 drive 10" extension bar.

I cleaned out the hex bolt head as best I could using cotton buds and plenty of WD40.

Then I fitted the hex socket to the extension bar and fed it through the (empty!) holes for the other rocker arm shafts. The extension bar was now parrallel to the camshaft and sticking out of the housing at the flywheel end...

I then attached one of my longer socket wrenches to the end of the extension. This set-up meant I could exert a huge amount of torque on the hex bolt, compared to the torque given by a 5mm hex key...

I was careful to push hard into the hex-bolt as I turned the socket wrench.

A squeak, a groan, and YES!!!! It was free!

The hex bolt is ruined, and has mashed itself onto the end of the hex socket but I should be able to save the hex socket and replace the hex bolt...

The reason the bolt was so tight? - Traces of RUST on the threads - this is the only rocker arm shaft which has any trace of rust on it, and I'll be inspecting its oil feed (from the perforated tube in the top of the cam housing) later on - rust INSIDE an engine is not a good sign, although its the first I've seen on this rebuild so far.

Obviously this technique couldn't apply exactly to one of the middle rocker arms...

But the moral is clear - ignore the pictures in the workshop manual showing hex keys for removing the rockers - use a 3/8 5mm hex socket and a long wrench instead!

- roGER (very happy!)

Most excellent. Thanx for the follow-up description. Who needs mechanics?

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'83 SC