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Pushrod tube seals replacement pictorial

Discussion in 'Engine & Transmission' started by Sarge, Jun 18, 2016.

  1. Sarge

    Sarge Member

    Messages:
    73
    Location:
    Falls Creek NSW
    I've just replaced the push rod tube seals on my 1800 engine. There are some good articles written on this but I wasn't able to easily find photos to help and I figured it would be a good idea to take photos so I could put the damn thing back together properly! Then I decided to share them with you in case, like me, you are somewhat new at this kombi stuff. I'll describe, step by step, what I did and what I learned. If you have any comment or tips, I and others would probably appreciate them.

    1) Get comfortable. Find the easiest way to get to the rocker covers. Jack up the car, remove the wheel, whatever it takes. I had removed the engine to get the gearbox reconditioned but the process is the same.
    2) Pry the rocker cover retainer downwards to remover the cover. (sorry, no pictures but you'll manage)
    This is what you will see

    [​IMG]

    3) You need to take note of how the retainer spring is fitted. These photos will help.

    [​IMG]

    [​IMG]

    4) Now loosen the rocker nuts, (there's 4), and take the retainer spring out, again taking note of how it fits in.
    5) Place a sheet of butchers paper, or something similar, on the floor or bench and write on it, as I have, so you can clearly see how things fit back together.
    6) Remove all the nuts and slide the rockers off and place them on the paper, with the retainer spring, as they were in the engine. They are spring loaded, so hold them with two hands as you pull them off.

    [​IMG]

    Part 2 coming
     
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  2. oldman

    oldman Super Moderator Staff Member

    Messages:
    8,025
    Location:
    Avalon Beach NSW
    Looking good so far....!
    Just the sort of thread that helps folks out....keep it coming :cool:
    Cheers,
    Mark
     
    Rosenrubes likes this.
  3. Sarge

    Sarge Member

    Messages:
    73
    Location:
    Falls Creek NSW
    7) Now you have access to the push rods and tubes.

    [​IMG]

    8) Remove the pushrods and place them on the sheet in the order you removed them.

    [​IMG]

    9) Now remove the pushrod tubes. Underneath the engine you will see the tubes. This is where you need to grasp the tubes to remover them. To do this I used a rubber glove and a pair of multi grips. Set the multi grips so that they gently grip the tube. Wrap the glove around the tube and the multi grips over the top of the glove. Now gently twist the tube back and forth with the multi grips. Try not to crush the tube. If you do dent it a little it won't matter too much. As long as the pushrod moves freely inside. Large dents will need to be removed. In the photo below you can see a lot of crud inside the housing. Remove all of this with parts cleaner, metho, white spirits, whatever you can. Do not scratch the housing. It will cause leaks.

    [​IMG]

    10) With the tube removed you can see the seals. In the photo below you can see that a lot of sealant has been used on the seals. From what I have read, this is not necessary and can cause the seals to leak. I have removed all of the sealant from the tubes and the heads. The inner seal was the same and there was sealant in the housing on the crank case so I gave it a good clean. Hopefully they won't leak. (the black seal is the inner seal and the green is the outer)

    [​IMG]


    Part 3 coming
     
    Last edited: Jun 18, 2016
  4. Sarge

    Sarge Member

    Messages:
    73
    Location:
    Falls Creek NSW
    11) Now clean it all up. Clean all the crud from the tubes. Remove the old seals and all of the sealant if there is any. A wire brush will get in to any nooks and crannies. Believe it or not, the tubes are silver! Remember to get all of the crud out of the seal housings on the head and the crankcase end. Once you have everything clean, replace the old seals. The back ones go on the small end (crankcase end) and the green go on the large end (head end). Put a bit of oil on them to allow them to slide in easier.

    [​IMG]
    [​IMG]

    12) Place the tube through the head (black seal inside) and into the crankcase. Push it in with your fingers and be sure it is fitting into the housing properly inside on the crankcase end. If it is not properly located when you tap it home you will damage the tube.

    [​IMG]

    13) Now using a dolly or a suitable sized socket on an extension, tap the seal home. Make sure whatever you use is as close to the size of the seal housing as possible.

    [​IMG]

    [​IMG]

    14) Now it's done!! Repeat for each tube and reassemble in the reverse order. Insert the pushrods and ensure they go all the way into the crankcase. Next put the rockers back on and do the nuts up finger tight. Remember to hold the rockers with two hands so they don't spring apart. You will notice that the clamps that hold them on have a gap at the bottom. Make sure this gap goes to the bottom as you need to slip the retainer spring into this gap. Replace the retainer spring making sure that it sits as per the photo and pushes on the end of the tubes. As you tighten up the nuts on the rockers, ensure that the pushrods sit properly in the cups at the bottom of the rocker arms. Now you will need to check the valve clearance (do the tappets). This is well explained in videos and on this forum.

    Good luck!!
     
    Last edited: Jun 18, 2016
    David H and Mordred like this.
  5. oldman

    oldman Super Moderator Staff Member

    Messages:
    8,025
    Location:
    Avalon Beach NSW
    Nice one Steve, "stuck" for posterity !
    Cheers,
    Mark
     
  6. Sarge

    Sarge Member

    Messages:
    73
    Location:
    Falls Creek NSW
    Cheers Mark,

    Just did a couple of edits to clarify a few things.

    Steve
     
  7. Mellow Yellow 74

    Mellow Yellow 74 Active Member

    Messages:
    805
    Location:
    Sydney
    Hopefully you have better luck with the black ones than I did. I originally used black o-rings for both inner and outer from Just Kampers and these went hard and leaked within a few months, then I replaced them with green ones from Mick Motors and these are fine. I think the green ones are viton so are good for oil whereas the black ones aren't.
     
  8. grumble

    grumble Active Member

    Messages:
    928
    Location:
    Taree
    Well done mate you have set it out so almost anyone should be able to understand the procedure. This is not a criticism just a little advice -in step 13 you use a drift to push the tube home, I found that the o ring can be lipped by the bore in the head which on some are very sharp. I take the sharp lip off with a scraper,use rubber grease in the bore and a wipe on the seal and then use a broomstick shaped to fit into the end of the tube to twist the tube into place and push it home. This means that you can feel the pressure and see the o ring distort prior to pinching the lip off. Tooley Imports have good quality seals at a reasonable price.Cheers for a great guide. Les
     
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  9. Sarge

    Sarge Member

    Messages:
    73
    Location:
    Falls Creek NSW
    Good tip Les. I hope to bench test before I re-install the motor. Hopefully they won't leak.
     
  10. 76kampa

    76kampa Active Member

    Messages:
    122
    Location:
    Perth
    I know this is an old post but I did not know the tube came out through the head :) Great.
     
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  11. Mordred

    Mordred Super Moderator Staff Member

    Messages:
    2,689
    Location:
    Penna, Hobart
    Only on Type IV engines I believe. Heads off on type 1. Got to be a bugger for them.

    Adrian
     
  12. Alpal

    Alpal Moderator Staff Member

    Messages:
    8,323
    Location:
    Melbourne Bend of Islands
    The question of sealer or not gets different answers. Just put mine back together as part of top end rebuild and did use a sealer. Time will tell.
     
  13. David H

    David H Well-Known Member

    Messages:
    3,439
    Location:
    newcastle
    My mech uses 'dry' so as you say 'time will tell'. Only 1.5,k since & that's so low to not count;). Normally get 60,k oil free with pushrod seal replacement:D.
    Cheers
     
    Last edited: Feb 13, 2018
  14. Gordon D

    Gordon D Active Member

    Messages:
    270
    Location:
    Brisbane
    Thanks for making this 'sticky' - am just about to embark on an educational rebuild so this is invaluable ... much appreciated :)
    Out of curiosity, when folks do go the sealant option (and it appears the jury is out on this one) what would be used ... and is there any need to grease the rings before relocating to assist in seating?
     
  15. cbus

    cbus Well-Known Member

    Messages:
    10,889
    Location:
    sunshine coast
    Cyril K2
    Good insurance. Easy install.
    Get the good seals.
     
  16. Gordon D

    Gordon D Active Member

    Messages:
    270
    Location:
    Brisbane
    Curil K2 maybe? Cyril K2 was bringing up some very weird results :p

    Generally available or specialist ... as I not Das Resto carry it
     
  17. cbus

    cbus Well-Known Member

    Messages:
    10,889
    Location:
    sunshine coast
    My spelling :)
    Prob fat fingers n not checked.
    Mick motors has it.
     
    Gordon D likes this.
  18. cbus

    cbus Well-Known Member

    Messages:
    10,889
    Location:
    sunshine coast
    Yeah. Other spelling not helpful :D
     
  19. Gordon D

    Gordon D Active Member

    Messages:
    270
    Location:
    Brisbane
    Hi guys, following on from this (and possibly a stupid question) but there were no retainer springs in my heads when I removed them ... are they essential?
    I am going to presume that my new heads will not come with retainer springs so need to know if I should get them.
     
  20. Mordred

    Mordred Super Moderator Staff Member

    Messages:
    2,689
    Location:
    Penna, Hobart
    Yes that are pretty inportant as otherwise there is only the seals stopping them working there way out leaving a large hole for oil to come out of. They should be available at most suppliers.

    Adrian
     
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