Stamped-Steel Rocker Arms - Brass Buttons

[More Power]

The plastic rocker arm buttons used with the 6.5 rocker arm assemblies came up recently here in our forum, which reminded me of a photo that member MJ McCarroll sent to me some years ago. I think it's worth having a look.

https://www.thedieselpageforums.com/tdpforum/attachment.php?attachmentid=5647&d=1604361126

As I recall, MJ used a specially hardened tap to thread the holes that were formerly used by the plastic buttons, then added bolts and brass washers in place of the plastic parts. I'd recommend using Loc-Tite 272 on the threads of the bolts.

My experience with the factory plastic buttons has been a good one. I've not had a problem, though I do replace them whenever I do cylinder head work.

Through the years, I've heard from a couple of other 6.5 owners who had varying degrees of problems with plastic button breakage. In one case, the buttons kept breaking even after replacing them... I suspect the root cause was a problem with the valve train that was causing the breakage (i.e. bent rocker, bent pushrod, bent valve stem or something other).

I liked MJ's idea, so I thought I'd show you all what he did. Thanks MJ!

[zippy555]

Im haven the same issue wih the buttons. new heads using the old valves and rockers. have had it break 3 differant buttons in less then 500 miles on new heads. I am going to tap and rplace with bolts and brass washers I was just hope that any one Or MJ Mcarrolcould tell me wharethey foundrhe rass washers atso donthave to waist timend mile looking. Thanks

[More Power]

I suspect MJ produced his own brass washers for his project using brass round stock and a lathe.

There must be an underlying cause of the button breakage in your situation. Something is bent, broken or out of alignment... or there is a piston clearance issue. something... something is out of the ordinary. Jim

[More Power]

I'm haven't the same issue with the buttons. New heads using the old valves and rockers. Have had it break 3 different buttons in less then 500 miles on new heads. I am going to tap and replace with bolts and brass washers I was just hope that any one Or MJ Mcarrol could tell me where they found the brass washers at so don't have to waste time looking. Thanks

You should be able to locate brass washers at a hardware store... like ACE. You may need to stack a couple to get the thickness you want, or you may need to chuck them in a drill/drill-press to file/sand the outer edges of the brass washers to match the diameter of the plastic buttons. The rocker shafts are pretty hard, so buy a quality tap, use cutting fluid and go slow. Some have suggested that instead of drilling/tapping the rocker shafts (to replace the plastic buttons) that we simply use the brass washers with bolts - along with good lock-nuts inside the rocker shafts. I suppose that would work too! I'm not opposed to this idea at all, assuming properly fitting & quality fasteners.

By the way, as of mid-November 2024 my daughter has driven her recently rebuilt 6.5TD about 5K miles following a full rebuild that included new plastic rocker arm locating buttons. So far, no problems... ;)