DIY Network

1962 Fort T-Bird: Manifold and Rocker-Arm Assembly From "Classic Car Restoration" episode DCR-305

The classic 1962 Ford Thunderbird sports roadster.

In this segment, the new aluminum manifold and the newly adjusted rocker-arm assembly are installed on the T-bird.

Materials:

Manifold upgrade kit and adjusted rocker-arm assembly
Standard automotive tools (socket wrenches, extensions, combination wrenches, screwdrivers, nut-drivers, etc.)
Torque wrenches
Air compressor and impact wrenches (optional)
RTV sealant
Lithium grease
Anti-seize compound
Brake cleaner

Safety Equipment:

Work gloves
Safety glasses or other eye protection

Safety Alert: Always wear eye protection when working with power tools or pneumatic tools.

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With the engine cylinder heads installed, now it's time to install the intake manifold.

Note: This is a summary of steps included in the automotive restoration procedures shown in this episode of Classic Car Restoration. These are general guidelines for restoration procedures on this particular make and model of vehicle, and for the level of restoration selected for this project. There may be variations in procedures depending on model, condition of vehicle, level of restoration undertaken and the types of replacement parts or upgrade kits selected. Always follow proper safety precautions, and read and follow manufacturer's guidelines, diagrams and safety notices that come with any replacement parts or kit that you select.
Steps:

• As with the cylinder heads, it's important to be sure that there's no grease or debris that will keep the manifold gaskets from sealing. Use some brake cleaner on a clean rag to wipe down the block sections and head.

• Before installation of the intake manifold, install the oil splash barrier by snapping it into place (figure A).

• Next, install the gasket end-seals. The end-seals that came in our kit have adhesive backing to secure them to the cylinder block. Double-check to make sure that the block is clean and absolutely free of grease. Remove the peel-off protective paper and press the end-seals into position (figure B).

  Figure A

  Figure B

  
  
• Install the gaskets themselves, making certain that they are oriented properly (figure C).

• To prevent leaks at the corners of the manifold where it meets the block and the heads, use some clear RTV sealant. Place a small amount in each of the four corner positions (figure D). Once the sealant dries, you can trim away any excess for a clean look.

  Figure C

  Figure D

  
  
• Now you can install the new aluminum intake manifold. Carefully lower the manifold into position (figure E). You may need to adjust the gaskets so that they lay flat and straight, and so the intake manifold sits snug against the heads

• Next, install the manifold bolts. Because the bolts are being threaded into aluminum, it's important to use some anti-seize compound to prevent galling of the threads. Thread and hand-tighten each of the manifold bolts to ensure that they thread properly, then go back and tighten each "hand-tight" with a socket wrench, making certain to avoid actually compressing the gasket.

• With the intake manifold's finger-tight in the manifold, now you can go back and tighten them down fully. According to our specs, we tightened the bolts using a spider pattern, working from the center-bolts outward. Work from bank to bank to evenly distribute the clamping load on the manifold (figure F).

  Figure F

  
  
• Next, install the push rods. For our Thunderbird, we opted to re-use the stock push rods. It's essential that each of the rods is perfectly straight. To make sure that they're straight, take the rods one at a time and roll them on a flat surface (figure G). If any one of the rods exhibits a bow, then replace it. A bent push rod will cause inaccurate valve timing.

• Once each of the push rods has been checked, put them in place -- making sure they're seated in the lifters. It's a good idea to use a little bit of white lithium grease on the end of each rod to prevent a dry start when the engine gets started later on.

• Now with the push rods in, it's time to now make the connection between the camshaft and the valve springs -- i.e., the rocker arms. Again, to prevent dry-starts and wear, put some lube on the tips of the valves (figure H) and on the upper ends of the push rods. Repeat these steps on the other side, lubricating each rod and tip.

  Figure G

  Figure H

  
  
• Install the rocker-arm assembly. Use a straight piece of wire (a piece of coat-hanger will do) to hold the push-rods up and out of the way while lining up the rocker assembly (figure I).

• When tightening down the rocker arm shaft, start in the center and work your way out. It is possible to bend the shaft, so tighten the bolts down evenly and from the center out (figure J). Repeat the steps on the other side.

  Figure I

  Figure J

  
  

In the segment that follows, a high-performance 4-barrel carburetor gets installed on the Thunderbird.

RESOURCES :

Classic Car Restoration Guide: The Complete Illustrated Step-By-Step Manual
Model: 1850108900
Author: Lindsay Porter
Order this book from Amazon.com
Haynes Publishing

Classic Car Restorer's Handbook: Restoration Tips and Techniques for Owners and Restorers of Classic and Collectible Automobiles
1557881944
Jim Richardson
(November 1994)
To order this title from Amazon, click here.
H.P. Books

Thunderbird Restoration Guide, 1958-1966 (Motorbooks International Authentic Restoration Guides)
by William Wonder
Published by Motorbooks International, June 1997
ASIN: 0760303908
To order this book from Amazon.com, click here.

Illustrated Thunderbird Buyer's Guide (Motorbooks International Illustrated Buyer's Guide)
by Paul G. McLaughlin
Publisher: Motorbooks International (July 2000)
ASIN: 0879388706
To order this book from Amazon.com, click here.

Edelbrock Performance Products
Website: www.edelbrock.com

GUESTS :

Keller Wallace
Keller Wallace Street Rods
Volunteer Street Rod Association
Knoxville, TN