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This is a bit of an odd one. The Comp CCA-35-512-8 should use a 6.248" stock length pushrod in a factory roller 302. Adding lift does take away from the base circle, but this isn't a "big" cam, and Comp calls it out as working with stock pushrods, so that alone shouldn't make the pushrods seem drastically too short.
Something else in the valvetrain stack is likely causing the discrepancy in pushrod length.
Lifter seat height
Collapsed or fast-bleed lifters
Valve tip height
Pedestal/rocker stack differences
That said, if those are Ford Performance FMS-M-6500-R302 lifters, they are intended as stock replacement hydraulic roller lifters, so we normally wouldn't expect a major seat height difference there.
Either way, you still want good geometry. Even with adjustable rockers, you’d still want to verify preload, rocker sweep pattern, etc. For those Ford Performance lifters, Ford recommends around .020"-.060" preload, or roughly 1/4 to 3/4 turn past zero lash.
We did order a pushrod length checker as well as some conversion studs and adjustable rockers from you guys. Hopefully this weekend we can get this sorted. It certainly is a mystery why things didn’t fit as well as expected. Aside from the rocker noise the truck idles and moves around the yard just fine.
My 78 f-250 have dummy gauges same with my 89 f150 and 90 f-250.
I don’t know about ‘78 but your ‘89 & ‘90 matches what I said about the real gauge ending sometime in ‘88. Because of customers complaining about the needle moving “too much”, Ford replaced the sending unit with a switch and put a resistor on the circuit board.
The truck is finally quiet, the studs and adjustable rockers did the trick. To further muddy the mystery though, we had only been working on the driver’s head until now. When we removed the passenger valve cover, all the rockers on that side were tight. We replaced them all anyway with studs and adjustable rockers. Why would all the rockers on one side be loose and tight on the other side.
My guess is that since you have a used motor with no knowledge of previous work, one head was milled more than the other or a thicker/thinner head gasket was used on one side. Those would affect the entire side. I guess the block could have been decked at not the same amount also.
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