Stator Assembly - Engine Stalling at Idle
Article No. 85-11-13STALLS - 5.0L - IDLE
FORD 1984-85 THUNDERBIRD, CROWN VICTORIA
LINCOLN-MERCURY 1984-85 COUGAR, GRAND MARQUIS, CONTINENTAL, MARK VII, LINCOLN
Engine stalls during extended idle or during idle after high speed driving in high ambient temperatures (+90~F) and high humidity (+80%) can be serviced by installing a new distributor stator assembly. The new stator has improved switching and higher temperature calibration.
Verify the symptom occurs during high ambient conditions. If verified, the stator assembly is suspect and should be replaced with stator assembly E5PZ-12A- 112-A using the procedure outlined.
1.6L EFI AND 1.6L EFI T/C DISTRIBUTOR WITH TFI
STATOR ASSEMBLY REPLACEMENT
Removal
1. Using a screwdriver, remove the distributor cap and position it and the attached wires aside so as not to interfere with work area.
2. Disconnect the TFI module from the harness.
3. Remove the distributor from the engine block.
4. Remove the rotor.
5. Remove the drive coupling spring with a small screwdriver or ice pick. Take care not to damage the drive coupling or spring.
6.a. Using an air hose, blow dirt and oil from the drive end of the distributor.
b. Put a small paint dot on the drive coupling and the shaft to note orientation for reassembly.
Figure 13 - DISTRIBUTOR SUPPORT TOOL D85P-12200-A:
c. Place the distributor support tool (Figure 13) in a vise and tighten or open the vise jaws wide enough to let pin drop out of the coupling but not so wide that the coupling is not supported.
d. Line-up the drive pin with the slot in the base.
7. With someone holding the distributor steady on the distributor support tool (D85P-12200-A) or vise, use a 5/32 inch diameter drift and hammer to drive the pin out of the shaft.
8. Remove the distributor from the fixture. Remove the drive coupling from the fixture and place aside for reassembly.
9. Before removing the shaft from the base, check for burrs on the end of the shaft and especially around the drive pin hole. If burrs are present, polish the shaft with emery paper and wipe clean before removing the shaft from the base to prevent damage to the lip seal and bushing in the base.
10. After assuring that there are no burrs, remove shaft assembly by gently pulling up on the shaft plate.
11. Remove the two screws holding the module to the base.
12. Remove the module. Wipe grease from the base and module, keeping surfaces free of dirt.
13. Remove the octane rod retaining screw.
14. Remove the octane rod assembly.
15. Remove the two screws retaining the stator connector in the bowl of the distributor. (Retain the screws for reassembly.)
16. Remove the stator assembly from the top of the bowl by gently lifting up.
17. Inspect the base bushing for wear or signs of excess heat concentration; replace the complete distributor assembly if damaged.
18. Inspect the shaft oil seal for tears or cuts; replace the complete distributor assembly if oil seal is damaged.
19. Carefully check the spring retainer that holds the shaft oil seal against the shaft - it must be present and have no kinks or breaks. Replace spring if necessary.
20. Inspect the base O-ring for cuts or damage and replace the O-ring if necessary.
21. Inspect base casting for cracks and wear. Replace complete distributor assembly if damage is found.
Re-assembly and Installation
1. Place the stator over the bushing and press down to seat.
2. Place the stator connector in position - tab should fit in the notch on the base and the fastening eyelets should be aligned with their screw holes.
3. Position the wires away from moving parts.
4. Reinstall the two stator screws and torque to specification (25-35 in.lbs.).
5. With the seal on the octane rod, insert in holes. Reinstall the octane rod through the base octane rod hole.
6. Place the end of the octane rod onto the same post as the original stator only (one post should easily fit in the octane rod hole).
7. Reinstall the octane rod screw and torque to specification (25-35 in.lbs.).
8. Wipe the back of the module and the distributor module mounting face free of all dirt.
9. Apply grease (No. WA10) to back of the module and spread evenly (thin, even coverage).
10. Turn the distributor base upside down so that the stator connector is in full view.
11. Insert the module, being sure that the three module pins are inserted into the stator connector.
12. Fully seat the module into the connector and against the base.
13. Reinstall the module screws and torque to specification (25-35 in.lbs.).
14. Apply a light coat of oil to the distributor shaft below the armature.
NOTE: Do not over-lubricate.
15. Insert the shaft assembly through the base bushing.
16. Place the drive coupling over the shaft and line up the paint dots that were made during disassembly. Start the pin into the drive coupling and shaft.
17. With someone holding the distributor steady on the support tool or vise, drive the pin into the shaft until the end of the pin is flush with the step in the drive coupling.
18. Check for free movement of the drive coupling on the pin and verify that the pin does not extend beyond the step in the coupling in either direction.
19. Remove the distributor from the fixture and check for free rotation.
20. Install the drive coupling spring in the groove on the drive coupling.
21. Install the distributor assembly in the engine.
22. Install the distributor cap and rotor.
23. Install the TFI module connector.
UNIVERSAL DISTRIBUTOR WITH EEC (OTHER THAN 1.6L)
STATOR ASSEMBLY REPLACEMENT
NOTE: Do not attempt to replace the stator without an arbor press.
Removal
1. Using a screwdriver, remove the distributor cap; position the cap and wires aside so as not to interfere with the work area. Remove TFI module connector.
2. Remove distributor from block per the distributor removal procedure.
3. Remove rotor.
4. Remove the two screws holding the TFI module to the base.
5. Remove the module, wipe the grease from the base and module, keeping the surfaces free of dirt.
6. If the distributor uses the push-on rotor, remove the two screws holding the armature and remove the armature.
NOTE: Hold the gear to loosen the armature screws; do not hold the armature.
7. To ease reassembly, mark with a felt tip pen, the armature, gear and collar, if present, (refer to the following chart) to note orientation.
8. Remove and discard pins in gear and collar if present (refer to chart).
GEAR GEAR
THRUST ROLL PIN COLLAR
ENGINE GEAR PIN WASHER EXTRUSION COLLAR PIN
2.3L HSC 67555-S FLUSH
2.3L OHC 67555-S FLUSH
2.8L 67575-S FLUSH
3.8L 67555-S FLUSH x 67555-S
4 9L 67775-S2 x EXTRUDE EVENLY,
BOTH SIDES
5.0L 67555-S FLUSH x 67555-S
6.1L 67775-S2 EXTRUDE EVENLY, x 67555-S
BOTH SIDES
7.0L 67775-S2 EXTRUDE EVENLY, x 67555-S
BOTH SIDES
7.5L 67775-S2 EXTRUDE EVENLY, x 67555-S
BOTH SIDES
Figure 14 - Bearing Removal Tool:
9. Invert the distributor and place in the axle bearing/seal plate (Tool T75L-1165-B) and press off the gear using the bearing removal tool (D84L- 1123-A) as shown in Figure 14.
10. Deburr and polish shaft with emery paper and wipe such that the shaft slides out freely from distributor base.
11. Remove shaft assembly.
12. Remove thrust washer from distributor shaft and retain.
13. Remove octane rod retaining screw and retain.
14. Remove octane rod assembly and retain.
15. Remove two stator assembly screws and retain.
16. Remove stator assembly from top of bowl.
17. Inspect base bushing for wear or signs of excess heat concentration; replace complete distributor assembly if damaged.
18. Inspect base O-ring for cuts or damage and replace O-ring if necessary.
19. Inspect base for cracks and wear. Replace complete distributor assembly if damage is found.
Re-assembly and Installation
1. Place the stator assembly over the bushing and press down to seat.
2. Place the stator connector in position - tab should fit in notch on base and fastening eyelets aligned with screw holes.
3. Position wires away from moving parts.
4. Install the two stator screws and torque to specification (25-35 in.lbs.).
5. Reinstall the octane rod, inserting rod through the base hole.
6. Place end of octane rod onto the same post as the original stator. Only one post should easily fit in rod hole.
7. Firmly seat octane rod seal into housing.
8. Reinstall the octane rod screw and torque to specification (25-35 in.lbs.).
9. If required, reinstall the thrust washer on top of the bushing.
10. Apply a light coat of oil to the distributor shaft below the armature.
11. Insert the shaft through the base bushing.
12. Place the collar, if required, over the shaft and line up mark on armature and collar to aid alignment with original drill hole. Use a drift punch to assure proper alignment.
NOTE: Drill holes through shaft and collar should align on both sides of shaft. If holes do not align, the collar may be 180~ out of alignment on the shaft. Rotate the collar on the shaft one half rotation and recheck.
13. Insert new roll pin (Part No. 67555-S) through collar and shaft. Pin should be flush with both sides of collar when sealed.
Figure 15 - Distributor:
14. If the distributor uses a push-on rotor, place a 1/2 inch deep well socket over the shaft (Figure 15), invert and place on arbor plate.
Figure 16 - Distributor with screw down rotor:
If the distributor uses a screw-down rotor, invert and place on arbor plate (Figure 16).
15. Place the distributor gear on the shaft and line up the mark on the armature and gear.
NOTE: The hole in the shaft and gear must be lined up as accurately as possible to assure ease of roll pin insertion.
Figure 17 - Shaft and Gear:
16. Place a 5/8 inch deep well socket over the shaft and gear (Figure 17) and press gear to align with original drill hole.
NOTE: If the gear holes do not align, the gear must be removed and repressed on. A drift punch will not align the holes. As in the collar, the holes should align.
17. Insert new roll pin (refer to chart following Step 8 in the removal procedure) through the gear and shaft. Pin should have proper extrusion, as referenced in same chart.
18. If the armature was removed, replace and torque screws to 25-35 in.-lbs.
19. Check distributor for free movement over full rotation of shaft.
NOTE: If the armature hits the stator, replace the entire distributor.
20. Wipe back of module and distributor module mounting face free of all dirt.
21. Apply grease (No. WA10) to the back of the module and spread evenly (thin, even coverage).
22. Turn the distributor base upside down such that the stator connector is in full view.
23. Insert the module and watch that the three module pins are inserted into the stator connector. Fully seat the module into the connector and against base.
24. Reinstall two module screws and torque to specification (25-35 in.-lbs.).
25. Reinstall the distributor into block per distributor replacement procedure.
26. Connect TFI module to wiring harness.
27. Replace rotor and torque screws to specification.
28. Replace cap and torque screws to specification.
29. Re-time engine.
PART NUMBER PART NAME CLASS
E5PZ-12A112-A Stator Assembly A
OTHER APPLICABLE ARTICLES: None
WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual.
OPERATION: 1265OD16
TIME: 1.0 Hr. DLR. CODING: Basic Part No. 12A112 - Code: L9