Engine Controls - Remove/install/overhaul: Overhaul Ford Thunderbird X

DISTRIBUTOR OVERHAUL

Note. Overhaul is not recommended on Escort 1.8L, Probe 2.2L Turbo & Tracer. If distributor is defective, replace entire unit.

Disassembly (Probe 2.2L Non-Turbo)

1. Remove distributor rotor and cover. Mark relation of drive gear to lower shaft. Remove retaining pin from drive gear. Remove retaining screw from center of signal rotor.
2. Pull signal rotor and pin from upper shaft using 2-Jawed Puller (D80L-1002-L). Note direction of arrow stamped into rotor. Disconnect 2 wires from pick-up coil, and mark for installation reference.
3. Remove 2 screws from pick-up coil. Remove pick-up coil. Remove 2 screws and pick-up coil mounting bracket. Remove "E" clip from stator plate. Remove 2 diaphragm mounting screws and vacuum diaphragm.
4. Remove 2 screws and stator plate. Remove upper shaft. Remove 2 retaining screws and lower shaft from distributor housing. Remove 2 "E" clips. Remove bearing and retainer from lower shaft. Remove seal from distributor housing.

Reassembly

1. Install seal into distributor housing. Install retainer and bearing onto lower shaft. Install weights and springs onto lower shaft. Install new "E" clips. Install upper shaft onto lower shaft.
2. Ensure weight pivot pins engage advance mechanism. Install upper and lower shaft assembly into distributor housing. Install stator plate into distributor housing. Install 2 retaining screws. Install vacuum diaphragm, "E" clip and 2 attaching screws.
3. Install pick-up coil mounting plate and pick-up coil. Install pick-up wiring harness and wires. Using a socket and hand pressure, press signal rotor and pin onto upper shaft until it bottoms against shoulder of upper shaft.
4. Note direction of arrow stamped into signal rotor. Install signal rotor retaining screw. Align groove in drive gear with alignment mark on distributor housing. Install retaining pin. Install cover, gasket and rotor.

Note. The TFI module on 3.8L and 5.0L HO Cougar and Thunderbird engines is not mounted on distributor. On Continental, Sable and Taurus, TFI module is located at right rear of engine compartment on cowling. On Cougar and Thunderbird, TFI module is located on right side of radiator support bracket.

Disassembly (Except Escort, Probe 2.2L & Tracer)

1. On models with distributor mounted TFI modules, remove 2 TFI-IV module screws. Pull right side of module down and back up distributor mounting flange to disengage module terminals from connector in distributor base. Remove module by pulling toward flange and away from distributor. CAUTION: Attempting to remove ignition module without first moving entire module toward distributor flange will break module pins at connector.
2. On all models, hold gear, and loosen armature screws. DO NOT hold armature. Remove screws and armature. Using a felt-tip pen, mark armature and gear for installation reference. Remove and discard roll pin in gear.
3. Place distributor in Axle Bearing Remover (T75L-1165-B). Press off gear using arbor press and Pinion Bearing Cone Remover (D79L-4621-A or D84L-112-A for 3.0L Probe). Using emery cloth, remove burrs from distributor shaft. Remove shaft from distributor assembly. (Scheme 10)or (Scheme 11).
4. Remove thrust washer from distributor (if equipped), and save for installation. On models with distributor mounted TFI module, remove screw and octane rod assembly. On all models, remove stator assembly screws and stator.
5. Inspect base bushing, "O" ring and distributor housing for wear, cracks or other damage. If necessary, replace "O" ring. If distributor housing or bushings are worn, replace entire distributor assembly.

Note. If distributor housing is cracked or worn, replace entire assembly.

Scheme 10

Scheme 11

1. Place stator assembly over bushing, and press down to seat. Place stator connector in position. Tab should fit in notch of base, and fastening eyelets should align with screw holes. Position wires away from moving parts. Install and tighten stator screws.
2. On models with distributor mounted TFI module, install octane rod through distributor base hole. Place end of rod onto same post as original stator. Install and tighten octane rod screw. On all models, lubricate distributor shaft, just below armature, with light oil. DO NOT overlubricate.
3. Install shaft through base bushing. Place a 1/2" deep well socket over shaft, invert assembly and place in arbor press. Place thrust washer (if equipped) and distributor drive gear on shaft. Align marks made during removal.
4. Place a 5/8" deep well socket over shaft and gear. Press gear until holes align with holes in shaft. If holes do not line up, press gear off and try again. DO NOT try to align holes using a drift or roll pin. Insert new roll pin through gear and shaft.
5. If armature has been removed, install armature. Tighten armature screws. Check distributor for freedom of rotation. If armature contacts stator, replace distributor. On models with distributor mounted TFI module, clean back of TFI ignition module and distributor contact plate.
6. Apply Silicone Dielectric Compound (D7AZ-19A331-A) to back of module, and spread evenly. Invert distributor base so stator connector is in full view. Insert TFI module.
7. Ensure module pins are inserted into stator connector. Fully seat TFI ignition module into connector and against base. Install and tighten TFI module screws.

SYNCHRONIZER ASSEMBLY (3.8L)