Finding rocker retainer clips suitable for FA20
 

Hello,

After experienced rocker arm failure first time on 2019, I've started to search solutions for it. At the time I started to search, there was no concrete solution for rocker arm failure. The one that requires head modification did provide only for exhaust sides. And my thought did not reach to the rocker arm clips.

On 2020, another BOOM occurred to my same RH head second time. A broken valve spring and a bent exhaust valve came also. WTF.

I was quite serious to find "never happen again" solution. I found Denstoj's rocker retainer clip kit and realized that those clips are stock parts of some cars. I searched again and asked local forum members who work for automotives. Finally I got that which clips will be matched to FA20.

I think the clips in the Denstoj's kit are Falcon V8's. The captured picture from his YouTube video like:
Attachment 200647
But those are not easy to get in South Korea.

Another candidate was a cilp used in Ford Mondeo 2.0 diesel engines. Also found in Citroen, Fiat, Lancia, Peugeot and SUZUKI. Part numbers are 0903.69, 0903.60, 0903.J4, 9651263580, 3M5Q6564BA or 1255011. These are easy to souce from ebay. Attachment 200648

But still I'd like to source parts from local part stores. Yeah, as you know there are Hyundai, Kia and some other manufacturers in South Korea. I found clips of Hyundai diesel engines, but those are slightly wider inner width so it seems like that it is hard to hold. In this picture, the older pivot with larger hole is clipped with Hyundai one. It actually has slight groove to hold, but doesn't look secure enough.
Attachment 200649

I decided to go with the second one. I get them from China with rocker arms and clips together. Sadly, no one sell the clips separately.

Pivots of our Fa20 should be modified using lathes. Have to give allowances to follow cam lobe movements. A pivot in the below is before making a groove. As you see, the clip cannot be inserted into the pivot without modification.

Attachment 200650

Attachment 200651

Attachment 200652

Finally installed into heads with new beehive springs.
Attachment 200653

I've drove over 5 months and 5000 km without issue in the clips. Reached over 7500 RPM several times. No weird sound.

AVCS has not been kicked in yet, but that is another problem.

Did you machine a groove into the pivots for the clip to latch into? I don't see it in any of your picture. Without a groove the clip has nothing to keep it on the pivot. That's why you have to send your pivots or purchase new ones with Denstoj's kit.

I've just not taken pictures of grooved pivots before installation.
As I remember about 1mm reduction in diameter. Easily done with lathes.

Attachment 200658

Attachment 200659

Attachment 200660

What is the part number of the parts you finally went with?

This seems like an effective alternative to the Denstoj kit for those willing to source the parts and do the machining.

Ford diesel's.
Copied from the part description:
S-MAX 2.0 /MONDEO IV/FOCUS/FOCUS II/GALAXY2.0 4HX/RHK/RHR /RHW ENGINE OEM:1255011/3M5Q6564BA

Did it require any special tooling?

I took a pivot to my regular automotive machinist and he said the pivot is hardened and would be extremely difficult to cut.

Thanks,
Keith

My mechanic did not use a special tooling but use a tooling installed in his lathe when we tested the feasibility. Guess that that neck is not hardened as the top half ball or the side.