Is it possible that a bad valve-rocker on a 96 3.8 could create enough clearance in the valve train for it to tap loudly?.. any help would be awesome, thanx!

 

Yes but unlikey.
In order of probability:
Rocker out of adjustment
Bent push rod
Bad lifter
Bad rocker
Worn out cam lobe
Damaged valve

 

well i re-adjusted my rockers (132 inch lbs plus an additional quarter turn), i checked all my push rods and there all in good shape, and i just replaced all my lifters. And while i was replacing my lifters i thoroughly checked out all cam lobes and couldnt see any obvious damage.... Also my head gasket recently went out so i just replaced my heads with new ones. It runs great but still has this insane tapping noise. the sounds eventually calms down but it still sounds bad.... any ideas?...thanks

 

Try to identify the noisy one first, and then take a good look. You may just have a bad lifter out of the box. Is your cam stock? What kind of lifters are you using?

 

I put a screw driver up to each cylinder location on the valve covers while the engine was running and it was loudest on the number 3 cylinder (center cylinder on the driver side). I recently removed the valve cover on that side on and just tried to re-adjust that cylinder. it didnt work so i took it off again and just completely removed both rockers and push rods on that side and when i started it the sound severely reduced in noise. all i could hear this time was my two free lifters dangling against the camshaft. My cam is stock and i bought stock lifters from the local parts store.. Thanx for all your help so far
(Also when i remove the valve covers i see no visible damage on the rocker or push rod, everything looks in good order, but there is a larger smack mark against the valve closest to the front of the engine, indicating more wear, yet they are both brand new?...lol)

 

i got same problem, loud clicking sound that goes up in beat while revving... i was told it's a header leak.