Hall Effect Sensor: Service and Repair

Removal Of Distributor Gear:

CAUTION
Do not attempt to replace stator without an arbor press.

The distributor drive gear is not released for service. If any nicks or cracks occur during the disassembly or assembly procedures, a new distributor must be installed. The distributor drive gear is matched to the distributor at assembly and should never be replaced.

Although some of the drive gears for other distributors may physically fit the distributor, they must not be used. Whenever damage or excessive wear is noted on the drive gear, a new distributor must be installed.

REMOVAL
1. Remove distributor assembly.
2. Loosen the armature attaching screws. While loosening screws, use a 5/16-inch allen wrench to hold distributor shaft stationary. Do not hold the distributor armature.
3. Remove two attaching screws and armature.
4. Mark thrust collar and drive gear with a felt tip pen for alignment reference when reinstalling distributor gear.
5. Remove and discard roll pin from the drive gear. Roll pin must also be removed and discarded from thrust collar.
6. Invert distributor and place in axle bearing/seal plate T75L-1165-B. Press off the gear using bearing pulling attachment D79L-4621-A or equivalent.
7. Remove thrust collar.
8. Deburr and polish shaft with emery cloth. Housing should slide freely on shaft.
9. Remove shaft assembly.
10. Remove attaching screw and stator.
11. Remove attaching screw and octane rod.
12. Inspect distributor housing bushing for wear or signs of excess heat concentration. Replace complete distributor if damaged.
13. Inspect distributor housing for cracks and wear. Replace complete distributor if damaged.
14. Inspect distributor housing O-ring for cuts or damage and replace O-ring if necessary.

INSTALLATION
1. Position stator and press downward to seat in distributor base.
2. Position wiring grommet in distributor base notch so that eyelets align with screw holes.
3. Position distributor stator connector wires away from any moving parts.
4. Install distributor stator assembly attaching screw and retainer. Tighten screw to 1.7-4.0 N.m (15-35 lb in).
5. Install octane rod, octane rod screw, and retainer. Tighten screw to 1.7-4.0 N.m (15-35 lb in).
6. Lubricate shaft assembly with a light coating of engine assembly lubricant D9AZ-19579D or equivalent fresh motor oil meeting Ford specification ESR-M99C80-A.
7. Install shaft assembly into distributor.
8. Place a 1/2 inch deep well socket over end of shaft assembly.
9. Invert distributor on arbor press.

NOTE:The hole in the drive gear and shaft assembly must be aligned as accurately as possible to allow for ease of the roll pin insertion. If the hole in the drive gear and shaft assembly will not align, the gear must be removed and installation attempted again. The gear cannot be turned for alignment.

10. Install collar and roll pin.
11. Install distributor gear on shaft assembly and align distributor gear with felt tip reference mark made at disassembly.
12. Place a 5/8 inch deep well socket centered around gear hole and press distributor gear onto shaft.
13. Install new roll pin through distributor gear. Pin should be flush.
14. Install distributor armature.

NOTE: Tighten armature attaching screws. While tightening screws, use an 5/16 allen wrench to hold distributor shaft stationary.

15. Install armature attaching screws and tighten to 2.8-4.0 N.m (25-35 lb in).

NOTE: If the distributor armature contacts the stator, the entire distributor must be replaced.

16. Rotate distributor shaft. Shaft should rotate freely, without any binding.
17. Install distributor assembly and reset ignition timing.