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IGNITION, FUEL SYSTEMS AND ELECTRICAL DISTRIBUTOR GEAR INSTALLATION The following information covers the installation of a new distributor gear onto an existing distributor. When replacing the distributor gear, it is important that you choose the appropriate gear for your application. If you have questions regarding your gear selection, please contact the Ford Racing Techline at (800) FORD788. Failure to use the correct gear will lead to premature gear failure. Premature gear failure may also be attributed to improper meshing of the gear teeth between the camshaft and distributor. For that reason, we recommend that you install a new ALTERNATIVE METHOD OF VERIFYING distributor gear when installing a new camshaft. CORRECT DISTRIBUTOR GEAR INSTALLATION INSTRUCTIONS: INSTALLATION: After STEP 7, install distributor assembly in the block you are using. Timing chain set and camshaft must be removed. STEP 1: Remove roll pin from distributor gear and shaft. Save pin With the aluminum distributor housing fully seated against for re-assembly. the block, verify that the distributor gear can be lifted off the support in the block at least .005". Next pull the distributor STEP 2: Verify that the shaft endplay is .024" to .035". Modify collar if gear down against the support in the block and hold it there. necessary. Some aftermarket distributors may be constructed Pull up on the aluminum distributor housing and verify that in a manner that does not allow you to achieve .024" to you can lift it up at least .005" while holding the gear against the .035" of endplay. See “Alternative method of verifying correct support in the block. This procedure will confirm that the gear distributor gear installation” if your distributor does not have is not being forced down against the support and not being .024" to .035" endplay. held up off the support in the block. STEP 3: Press original distributor gear off shaft. Continue with STEP 8. STEP 4: Mark location of original roll pinhole on the shaft by drawing COMMON DISTRIBUTOR PROBLEMS: a vertical line along the shaft that intersects the hole. Measure Distributors with very little or no shaft endplay. This has been found from the center line of the roll pinhole to a fixed point above it. with new and remanufactured distributors. Improper endplay may force Note that dimension. the gear against the support in the block or hold it up off the support, causing damage. STEP 5: Press new distributor gear onto shaft. NOTE: Replacement distributor gear does not have roll Distributors that have a different material gear than advertised. It is pinhole. important to run the correct distributor gear for the camshaft that you are using. Consult the manufacturer of the camshaft you are using for STEP 6: Pull distributor shaft out of distributor housing to eliminate gear recommendation. endplay (see Figure 1). Some heavy-duty oil pump drive shafts may not allow an EFI distributor STEP 7: Check location of distributor gear on distributor shaft (see to slide down far enough over the oil pump drive shaft. EFI distributors Figure 1). If it is not in the correct location, use a press to have a longer shaft below the gear. move the gear to the correct location. Running an HV oil pump with production bearing clearances can cause STEP 8: Using the vertical line on the distributor shaft and the noted abnormally high oil pressure and possible premature distributor gear wear. dimension (see STEP 4), roughly plot where the original roll pinhole is located. Drill a new .125" hole 90˚ from the original Gears on camshafts with a very poor finish. This could cause premature hole, above or below it, through the gear and the shaft. NOTE: It is important that the dimensions called out in distributor gear wear. Figure 1 are maintained while drilling. New and remanufactured distributors with the gear installed at the wrong height. STEP 9:Insert roll pin and check dimensions (see Figure 1). WARNING: If the distributor gear is installed incorrectly, it may be forced down against the support in the block or may be held up away from the support in the block. Both conditions will cause damage to the block and or the block and gears. When the gear is properly installed, the cut on the gears and the direction of rotation will pull the distributor gear down against the support (distributor gear thrust face) in the block. For important information about the proper usage of performance parts, please see page 14. See pages 286-292 for important safety, emissions and warranty information. www.fordracingparts.com 223


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