Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSFORD1996E 350 VAN V8-460 7.5LREPAIR AND DIAGNOSISSPECIFICATIONSMECHANICAL SPECIFICATIONSENGINESYSTEM SPECIFICATIONSENGINE REBUILDING SPECIFICATIONS
1996 Ford E 350 Van V8-460 7.5L
Engine Rebuilding Specifications
1996 Ford E 350 Van V8-460 7.5LSECTION Engine Rebuilding Specifications
Cylinder Head Warpage Limit 0.006 in
Valve Guide Inside Diameter (Std.) 0.3433-0.3443 in
Valve Stem To Guide Clearance 0.0010-0.0027 in
Valve Seat Angle 45°
Valve Seat Width 0.0600-0.0800 in
Valve Seat Runout 0.002 in
Valve Spring Free Length 2.06 in
Valve Spring Out Of Square Limit 0.078 in
Valve Spring Pressure (lb @ in)
Closed 76-84 @ 1.8100
Open 218-240 @ 1.3300
Valve Stem Diameter (Std.) 0.3415-0.3423 in
Maximum Valve Tip Refinish 0.01 in
Valve Face Angle 44°
Minimum Margin 1/32 in
Valve Clearance 0.1000-0.1500 in
Camshaft Journal Diameter 2.1238-2.1248 in
Camshaft Bearing Inside Diameter 2.1258-2.1268 in
Camshaft Bearing Clearance 0.0010-0.0030 in
Camshaft Endplay 0.0010-0.0060 in
Camshaft Runout (Max.) 0.005 in
Lifter Bore Diameter 0.8752-0.8767 in
Lifter Diameter (Std.) 0.8740-0.8745 in
Lifter to Bore Clearance 0.0007-0.0027 in
Crankshaft Main Bearing Journal Diameter 2.9994-3.0002 in
Connecting Rod Journal Diameter 2.4992-2.5000 in
Maximum Main Journal Taper 0.0005 in
Maximum Rod Journal Taper 0.0006 in
Journal Runout Limit 0.002 in
Main Bearing Clearance 0.0008-0.0015 in
Connecting Rod Bearing Clearance 0.0008-0.0015 in
Thrust Bearing Clearance 0.0040-0.0080 in
Connecting Rod Side Clearance 0.0100-0.0200 in
Connecting Rod Pin Bore Diameter 1.0386-1.0393 in
Piston Pin Bore Diameter 1.0401-1.0406 in
Piston Pin Diameter (Std.) 1.0398-1.0403 in
Pin to Piston Bore Clearance 0.0002-0.0005 in
Piston Ring Maximum End Gap
Compression Rings 0.0100-0.0200 in
Oil Ring 0.0100-0.0300 in
Piston Ring Side Clearance
Compression Rings 0.0012-0.0022 in
Oil Ring Snug Fit
Bore Diameter (Std.) 4.3600-4.3636 in
Bore Out Of Round Service Limit 0.005 in
Cylinder Taper Service Limit 0.01 in
Deck Warpage Service Limit 0.006 in
Main Bearing Bore Diameter (Std.) 3.1922-3.1934 in
Oil Pump Rotor Backlash 0.0120 in
Oil Pump Rotor To Body Clearance 0.0010-0.0130 in
Oil Pump Rotor End Clearance [01] 0.0040 in
Oil Pump Driveshaft To Pump Body Clearance 0.0015-0.0030 in
Oil Pump Relief Valve To Body Clearance 0.0015-0.0030 in
Oil Pump Relief Spring Pressure (lb @ in) 20.6-22.6 @ 2.4900
Valve Guide Inside Diameter (Std.) 0.3433-0.3443 in
Valve Stem To Guide Clearance 0.0010-0.0027 in
Valve Seat Angle 45°
Valve Seat Width 0.0600-0.0800 in
Valve Seat Runout 0.002 in
Valve Spring Free Length 2.06 in
Valve Spring Out Of Square Limit 0.078 in
Valve Spring Pressure (lb @ in)
Closed 76-84 @ 1.8100
Open 218-240 @ 1.3300
Valve Stem Diameter (Std.) 0.3415-0.3423 in
Maximum Valve Tip Refinish 0.01 in
Valve Face Angle 44°
Minimum Margin 1/32 in
Valve Clearance 0.1000-0.1500 in
Camshaft Journal Diameter 2.1238-2.1248 in
Camshaft Bearing Inside Diameter 2.1258-2.1268 in
Camshaft Bearing Clearance 0.0010-0.0030 in
Camshaft Endplay 0.0010-0.0060 in
Camshaft Runout (Max.) 0.005 in
Lifter Bore Diameter 0.8752-0.8767 in
Lifter Diameter (Std.) 0.8740-0.8745 in
Lifter to Bore Clearance 0.0007-0.0027 in
Crankshaft Main Bearing Journal Diameter 2.9994-3.0002 in
Connecting Rod Journal Diameter 2.4992-2.5000 in
Maximum Main Journal Taper 0.0005 in
Maximum Rod Journal Taper 0.0006 in
Journal Runout Limit 0.002 in
Main Bearing Clearance 0.0008-0.0015 in
Connecting Rod Bearing Clearance 0.0008-0.0015 in
Thrust Bearing Clearance 0.0040-0.0080 in
Connecting Rod Side Clearance 0.0100-0.0200 in
Connecting Rod Pin Bore Diameter 1.0386-1.0393 in
Piston Pin Bore Diameter 1.0401-1.0406 in
Piston Pin Diameter (Std.) 1.0398-1.0403 in
Pin to Piston Bore Clearance 0.0002-0.0005 in
Piston Ring Maximum End Gap
Compression Rings 0.0100-0.0200 in
Oil Ring 0.0100-0.0300 in
Piston Ring Side Clearance
Compression Rings 0.0012-0.0022 in
Oil Ring Snug Fit
Bore Diameter (Std.) 4.3600-4.3636 in
Bore Out Of Round Service Limit 0.005 in
Cylinder Taper Service Limit 0.01 in
Deck Warpage Service Limit 0.006 in
Main Bearing Bore Diameter (Std.) 3.1922-3.1934 in
Oil Pump Rotor Backlash 0.0120 in
Oil Pump Rotor To Body Clearance 0.0010-0.0130 in
Oil Pump Rotor End Clearance [01] 0.0040 in
Oil Pump Driveshaft To Pump Body Clearance 0.0015-0.0030 in
Oil Pump Relief Valve To Body Clearance 0.0015-0.0030 in
Oil Pump Relief Spring Pressure (lb @ in) 20.6-22.6 @ 2.4900
RENDER: 1.0x
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.