Lifter noise?

[Alk-3]

The pushrod wasn't properly seated in the tappet upon reassembly.

correct. that's what I assumed as soon as I saw the pushrod was stuck.

[SafeAirOne]

correct. that's what I assumed as soon as I saw the pushrod was stuck.

I figured as much. Your write-up questioned if it would happen as you're driving down the road in the future. It won't--if the rod is seated in the socket and the rocker is adjusted.

[Alk-3]

I figured as much. Your write-up questioned if it would happen as you're driving down the road in the future. It won't--if the rod is seated in the socket and the rocker is adjusted.

that's what I wanted to hear. I will replace the tappet once I get a few days in a row to tear it down, but in the meantime I'm going to assume it's okay for now. If by chance it does happen as I drive, would pulling the plug on the cylinder be wise just to get it home?

[SafeAirOne]

If by chance it does happen as I drive, would pulling the plug on the cylinder be wise just to get it home?

EDIT: Oh...I just realized that you said you're going to drive it without replacing that tappet (or at least checking it). It is a soft, crumbly metal, so I personally wouldn't risk it. It could be shattered, which could very well lead to all sorts of nastiness. END EDIT.


BTW, I'd check to make sure that #8 lifter that wasn't seated is straight before ordering parts. The book says to roll it along a flat surface and look for a wobble.

[Alk-3]

EDIT: Oh...I just realized that you said you're going to drive it without replacing that tappet (or at least checking it). It is a soft, crumbly metal, so I personally wouldn't risk it. It could be shattered, which could very well lead to all sorts of nastiness. END EDIT.

I'd be more concerned about running it at all with a lifter bouncing around, crunching up the tappet, setting the cam follower free to mangle up the camshaft and head. Limping it home could turn a simple lifter and tappet R&R into a whole new head and camshaft.

BTW, I'd check to make sure that #8 lifter that wasn't seated is straight before ordering parts. The book says to roll it along a flat surface and look for a wobble.

as the day wore on and I gave it some more thought, I've decided to go ahead and replace the broken part, even though it does seem solid right now.. I just had zero interest in once again pulling the head off this motor… I'm SO tired of it. every time I pull it off something else goes wrong, and it's just getting silly now.
I will get a new pushrod, and a whole new lifter assembly, new head gasket (AGAIN!) and go for it.
does anyone know if I could get just a head gasket somewhere. I've only been able to find the whole gasket set.. I have way more gaskets than I could ever use.
sooo any tips on how to remove the cam follower and lifter assembly with the tappet? I understand I have to remove a setscrew that has a safety wire threaded through it..

[SafeAirOne]

Upon further research, it seems the cam follower (tappet roller) shouldn't be able to fall into the cam area even though the tappet is completely destroyed unless the tappet guide itself is raised (which it won't be unless you remove the safety-wired set screw). In other words, it appears as if cam and block (not head, as I mis-stated earlier) damage shouldn't be an issue with your current situation, at least not from the cam follower falling into the cam compartment. I've retracted my earlier post regarding this.

Still, I'd probably want to change that tappet if it has a piece missing. I wouldn't bother with the lifter if it is still straight, and head gaskets alone are available almost everywhere.

[Alk-3]

Upon further research, it seems the cam follower (tappet roller) shouldn't be able to fall into the cam area even though the tappet is completely destroyed unless the tappet guide itself is raised (which it won't be unless you remove the safety-wired set screw). In other words, it appears as if cam and block (not head, as I mis-stated earlier) damage shouldn't be an issue with your current situation, at least not from the cam follower falling into the cam compartment. I've retracted my earlier post regarding this.

Still, I'd probably want to change that tappet if it has a piece missing. I wouldn't bother with the lifter if it is still straight, and head gaskets alone are available almost everywhere.

Okay, that's good news. I was wondering if this would really be a problem, but I don't really want to risk anything. So now I have a fear of the roller dropping into the cam compartment.. it says to make an appropriate wire clip.. what does that mean? I'm sure once I pull it out it will be obvious, but at that point it might be too late.. the way this project has been progressing I will almost be shock if it doesn't fall into the cam compartment.

[SafeAirOne]

Okay, that's good news. I was wondering if this would really be a problem, but I don't really want to risk anything. So now I have a fear of the roller dropping into the cam compartment.. it says to make an appropriate wire clip.. what does that mean? I'm sure once I pull it out it will be obvious, but at that point it might be too late.. the way this project has been progressing I will almost be shock if it doesn't fall into the cam compartment.

Well, an undamaged tappet should just slide right up the groove in the tappet guide (#11 in the diagram), but you have to remove the set screw (labeled 6,12 & 15) in order to slide the tappet all the way out. The key is to make sure the tappet guide (#11) doesn't ride up in the bore, allowing the tappet roller to fall into the cam compartment while you're fetching the tappet.

It's not as hard as it sounds. All you need is a stiff wire with a small hook bent on the end of it. Something that will pass through the front or rear gap between the tappet and the guide and hook on the recess in the side of the tappet and pull it up. The other option is if you have some pretty long needle-nosed pliers that you can just grab the tappet with and pull it out. A magnetic pick-up tool will probably get the tappet roller out, or you could use the hooked wire.

Should the tappet guide somehow be raised, allowing the tappet roller to fall into the cam compartment, it's not the end of the world, though it is a PITA. Just male sure you do not rotate the engine. You'll have to remove the fuel pump and rear cam cover and retrieve the tappet roller.