I had that same problem immediately after reassembling the heads on my 3.5 after doing valve jobs and valve stem seals - I had 2 rocker arms come off, one fell completely off and the other got wedged diagonally and put a huge gouge in the cam lobe. I ended up replacing the cam and both rockers for peace of mind but never did figure out why they came off. It ran like crap and made lots of noise just like yours is doing - that would be a far easier and inexpensive fix than replacing the motor.

The diagnosis is that your motor sucked in a butterfly valve, but what got damaged that is causing it to run poorly? Does the shop think that it only bent valves? That's not a terribly difficult fix either - a few valves and guides, plus new gaskets and valve stem seals just because you're there.

Lloyd's truck doesn't have butterfly valves, they found that stuff in the exhaust (likely from the old motor). Lloyd also said they put a bore camera down the sparkplug and it didn't look like it had any piston damage.

I looked at the video a minute ago, they were installing an old alignment machine they just bought after hours. I am not convinced there is any damage to the piston. The dimples look like the type of half moons you usually see, and the damage on the edge may just be some camera fuzz.

Here is the thing, once it comes apart, it comes apart until its fixed and I wont be able to move it. So it is a commitment.

Well... pulling it apart down to the valve covers should'nt be too bad huh?

I assume not, but not sure what has to come off and what evil, hidden bolts will be found. If needed I can leave it so it can be still be winched onto a trailer, but it will be a non-runner once it comes apart. If I was going to tear it down it would be over the weekend.

It's not that bad, i've only had to tear down the top end a few times and it's been so long between jobs i'm learning it again each time really. Even just making it up as i go it always seems to go alright. Maybe get some pointers from PA_JERO he knows some tricks to make it faster.

Plenum and valve covers should only take about an hour or two tops. It's not hard, just label the plug wires as you disconnect them just in case. Wiring harness on top of the plenum is super simple, nothing will plug into an area if it doesn't belong because the plugs are specific fit to each other.

Ok, will give it a shot Saturday Morning......

If you're not sure about the age or condition of your plugs and wires, this is the time to replace them. The plug wires especially are much easier to access when the plenum is off.

Whether you've replaced them already is probably mentioned somewhere earlier in this build thread but I don't have the time to hunt through it all to find out. <img src="/forums/images/graemlins/smile.gif" alt="" />

Ok. What accessories do I have to take off? Pulled it under the carport for tomorrow, I cannot believe it fit!