Ford F-350 Distributor Removal With Diagrams

Ford Distributor Removal

REMOVAL

Carbureted Engines (DuraSpark II)

See Figure 1

Fig. Fig. 1: Distributor assembly. Arrow points to front

1. Remove the air cleaner assembly, taking note of the hose locations.
2. Disconnect the distributor wiring connector from the vehicle wiring harness.
3. Noting the position of the vacuum line(s) on the distributor diaphragm, disconnect the lines at the diaphragm. Unsnap the two distributor cap retaining clamps and remove the cap, rotor and adapter.

If it is necessary to disconnect ignition wires from the cap to get enough room to remove the distributor, make sure to label every wire and the cap for easy and accurate reinstallation.

4. Rotate the engine to align any pole on the armature with the pole on the stator.
5. Install the rotor. Using chalk or paint, carefully mark the position of the distributor rotor in relation to the distributor housing and mark the position of the distributor housing in relation to the engine block. When this is done, you should have a line on the distributor housing directly in line with the tip of the rotor and another line on the engine block directly in line with the mark on the distributor housing. This is very important because the distributor must be installed in the exact same location from which it was removed, if correct ignition timing is to be maintained.
6. Remove the distributor hold-down bolt and clamp. Remove the distributor from the engine. Make sure that the oil pump (intermediate) driveshaft does not come out with the distributor. If it does, remove it from the distributor shaft, coat its lower end with heavy grease, and reinsert it, making sure that it fully engages the oil pump drive.

Do not disturb the engine while the distributor is removed. If you turn the engine over with the distributor removed, you will have to re-time the engine.

INSTALLATION-ENGINE NOT ROTATED

Carbureted Engines (DuraSpark II)

1. If the engine was not cranked (disturbed) when the distributor was removed, position the distributor in the block with the armature and stator poles aligned, the rotor aligned with the mark previously scribed on the distributor body and the marks on the distributor body and cylinder block in alignment. Install the distributor hold-down bolt and clamp finger-tight.
2. If the stator and armature poles cannot be aligned by rotating the distributor, pull the distributor out just far enough to disengage the drive gear and rotate the distributor shaft to engage a different gear tooth.
3. Install the distributor cap and wires.
4. Connect the distributor wring connector to the wiring harness. Tighten the hold-down bolt.
5. Install the air cleaner, if removed.
6. Check the ignition timing, as outlined in Routine Maintenance .

INSTALLATION-CRANKSHAFT OR CAMSHAFT ROTATED

Carbureted Engines (DuraSpark II)

If the engine is cranked (disturbed) with the distributor removed, it will now be necessary to re-time the engine.

1. Rotate the engine so that No. 1 piston is at TDC of the compression stroke.
2. Align the timing marks to the correct initial timing shown on the underhood decal.
3. Install the distributor with the rotor in the No. 1 firing position and any armature pole aligned with the stator pole.

Make sure that the oil pump intermediate shaft properly engages the distributor shaft. It may be necessary to crank the engine after the distributor gear is partially engaged in order to engage the oil pump intermediate shaft and fully seat the distributor in the block.

4. If it was necessary to rotate the engine to align the oil pump, repeat Steps 1, 2 and 3.
5. Install the hold-down bolt finger tight.
6. Install the distributor cap and wires.
7. Connect the distributor wring connector to the wiring harness. Tighten the hold-down bolt.
8. Install the air cleaner, if removed.
9. Check the ignition timing.
10. When everything is set, tighten the hold-down bolt to 25 ft. lbs. (34 Nm).

REMOVAL

Fuel Injected Engines (TFI-IV Systems)

See Figures 2 and 3

Fig. Fig. 2: Remove the hold-down bolt to the distributor-fuel injected engine shown

Fig. Fig. 3: Remove the distributor from the engine

1. Disconnect the primary wiring connector from the distributor.
2. Mark the position of the cap's No. 1 terminal on the distributor base.
3. Unclip and remove the cap. Remove the adapter.
4. Remove the rotor.
5. Remove the TFI connector.
6. Matchmark the distributor base and engine for installation reference.
7. Remove the hold-down bolt and lift out the distributor.

INSTALLATION

Fuel Injected Engines (TFI-IV System)

1. Rotate the engine so that the No. 1 piston is at TDC of the compression stroke.
2. Align the timing marks so that the engine is set at the initial timing shown on the underhood sticker.
3. Install the rotor on the shaft and rotate the shaft so that the rotor tip points to the No. 1 mark made on the distributor base.
4. Continue rotating the shaft so that the leading edge of the vane is centered on the vane switch assembly.
5. Position the distributor in the block and rotate the distributor body to align the leading edge of the vane and vane switch. Verify that the rotor tip points to the No. 1 mark on the body.

If the vane and vane switch cannot be aligned by rotating the distributor body in the engine, pull the distributor out just far enough to disengage the gears and rotate the shaft to engage a different gear tooth. Repeat Steps 3, 4 and 5.

6. Install and finger tighten the hold-down bolt.
7. Connect the TFI and primary wiring.
8. Install the rotor, if not already done.

Coat the brass portions of the rotor with a¹/32in. (0.8mm) thick coating of silicone dielectric compound.

9. Install the cap and adapter (as necessary). Install the wires and start the engine.
10. Check and set the initial timing.
11. Tighten the hold-down bolt to 25 ft. lbs. (34 Nm).

INSPECTION

1. Remove the distributor cap and rotor.
2. Wash the inside and outside of the cap and wash the rotor with soap and water, then dry them thoroughly with compressed air or a lint-free cloth.
3. Look closely at the distributor cap, inspecting it for signs of deterioration such as cracks, broken carbon button or carbon tracks.
4. Inspect the terminals for dirt or corrosion.
5. Inspect the rotor for carbon build-up, cracks or damage to the blade or spring.
6. If damage is found, replace the distributor cap and/or rotor.

STATOR ASSEMBLY REPLACEMENT

Carbureted Engines

1. Disconnect the battery ground cable.
2. Remove the distributor cap.
3. Remove the rotor.
4. Unclip and remove the upper distributor body.
5. Remove the retaining screw and remove the wire harness from the distributor.
6. Using a small gear puller, remove the stator from the distributor shaft. As the stator is pulled up on the shaft, take care to hold on to the roll pin so that it doesn't fall into the distributor.

To install:

7. Place the new stator on the shaft, press or dive it down slightly, insert the roll pin and drive it into place inside the stator.
8. Using a deep socket, or similar tool, drive the stator down until it bottoms. Check occasionally to be sure that the roll pin stays in place.
9. Install the wiring harness, upper body, rotor and cap.

Fuel Injected Engines
V8 ENGINES

1. Remove the distributor assembly from the engine; refer to the procedure in this section.>
2. Remove the ignition rotor from the distributor shaft.
3. Mark the armature and distributor drive gear with a felt tip pen or equivalent, to note their orientation. While holding the distributor gear, remove the 2 armature retaining screws and remove the armature.

Do not hold the armature to loosen the screws.

4. Use a suitable punch to remove the roll pin from the distributor drive gear; discard the roll pin.
5. Position the distributor upside down in a suitable press. Using a press plate and suitable driver, press off the distributor drive gear.
6. Use a file and/or emery paper to remove any burrs or deposits from the distributor shaft, that would keep the shaft from sliding freely from the distributor housing. Remove the shaft assembly.
7. Remove the 2 stator assembly retaining screws.
8. Remove the octane rod and screw.
9. Remove the stator assembly.
10. Inspect the base bushing for wear or signs of excess heat concentration. If damage is evident, the entire distributor assembly must be replaced.
11. Inspect the base O-ring for cuts or damage and replace, as necessary.
12. Inspect the base for cracks and wear. Replace the entire distributor assembly if the base is damaged.

To install:

13. Position the stator assembly over the bushing and press down to seat.
14. Position the stator connector. The tab should fit in the notch on the base and the fastening eyelets should be aligned with the screw holes. Be sure the wires are positioned out of the way of moving parts.
15. Install the 2 stator retaining screws and tighten to 15-35 inch lbs. (1.7-4.0 Nm). Install the octane rod.
16. Apply a thin coat of clean engine oil to the distributor shaft below the armature. Insert the shaft into the distributor base.
17. Place a ¹ / 2 in. deep well socket over the distributor shaft, invert the assembly and place on the press plate.
18. Position the distributor drive gear on the end of the distributor shaft, aligning the marks on the armature and gear. Make sure the holes in the shaft and drive gear are aligned, so the roll pin can be installed.
19. Place a ⁵ / 8 in. deep well socket over the shaft and gear and press the gear until the holes are aligned.

If the shaft and gear holes do not align, the gear must be removed and repressed. Do not attempt to use a drift punch to align the holes.

20. Drive a new roll pin through the gear and shaft.
21. Install the armature and tighten the screws to 25-35 inch lbs. (2.8-4.0 Nm).
22. Check that the distributor shaft moves freely over full rotation. If the armature contacts the stator, the entire distributor must be replaced.
23. Make sure the back of the TFI-IV module and and the distributor mounting face are clean. Apply silicone dielectric compound to the back of the module, spreading thinly and evenly.
24. Turn the distributor base upside down, so the stator connector is in full view.
25. Install the ignition rotor onto the distributor shaft. Install the distributor as described in this section.

4.9L ENGINE

1. Remove the distributor assembly from the engine; refer to the procedure in this section.
2. Remove the ignition rotor from the distributor shaft.
3. Mark the armature and distributor drive gear with a felt tip pen or equivalent, to note their orientation. While holding the distributor gear, remove the 2 armature retaining screws and remove the armature.

Do not hold the armature to loosen the screws.

4. Use a suitable punch to remove the roll pin from the distributor drive gear; discard the roll pin.
5. Position the distributor upside down in a suitable arbor press. Using a press plate and suitable driver, press off the distributor drive gear.
6. Remove the thrust washer and save it.
7. Use a file and/or emery paper to remove any burrs or deposits from the distributor shaft, that would keep the shaft from sliding freely from the distributor housing.
8. Remove the shaft assembly.
9. Remove the 2 stator assembly retaining screws.
10. Remove the octane rod and screw.
11. Remove the stator assembly.
12. Inspect the base bushing for wear or signs of excess heat concentration. If damage is evident, the entire distributor assembly must be replaced.
13. Inspect the base O-ring for cuts or damage and replace, as necessary.
14. Inspect the base for cracks and wear. Replace the entire distributor assembly if the base is damaged.

To install:

15. Position the stator assembly over the bushing and press down to seat.
16. Position the stator connector. The tab should fit in the notch on the base and the fastening eyelets should be aligned with the screw holes. Be sure the wires are positioned out of the way of moving parts.
17. Install the 2 stator retaining screws and tighten to 15-35 inch lbs. (1.7-4.0 Nm). Install the octane rod.
18. Apply a thin coat of clean engine oil to the distributor shaft below the armature. Insert the shaft into the distributor base. Install the thrust washer.
19. Place a ¹ / 2 in. deep well socket over the distributor shaft, invert the assembly and place on the press plate.
20. Position the distributor drive gear on the end of the distributor shaft, aligning the marks on the armature and gear. Make sure the holes in the shaft and drive gear are aligned, so the roll pin can be installed.
21. Place a ⁵ / 8 in. deep well socket over the shaft and gear and press the gear until the holes are aligned.

If the shaft and gear holes do not align, the gear must be removed and repressed. Do not attempt to use a drift punch to align the holes.

22. Drive a new roll pin through the gear and shaft.
23. Install the armature and tighten the screws to 25-35 inch lbs. (2.8-4.0 Nm).
24. Check that the distributor shaft moves freely over full rotation. If the armature contacts the stator, the entire distributor must be replaced.
25. Make sure the back of the TFI-IV module and and the distributor mounting face are clean. Apply silicone dielectric compound to the back of the module, spreading thinly and evenly.
26. Turn the distributor base upside down, so the stator connector is in full view.
27. Install the ignition rotor onto the distributor shaft. Install the distributor, as described in this section.

VACUUM DIAPHRAGM ASSEMBLY REPLACEMENT

1. Disconnect the diaphragm assembly vacuum hose(s).
2. Remove the C-clip securing the diaphragm rod to the base plate pin. Lift the diaphragm rod off the base plate pin.
3. Remove the 2 diaphragm assembly attaching screws and identification tag.
4. Remove the diaphragm assembly from the distributor base.

To install:

5. Adjust the new diaphragm assembly per manufacturer's instructions included with the new diaphragm.
6. Install the diaphragm on the distributor base. Attach the diaphragm assembly and identification tag to the distributor base with the 2 attaching screws and tighten to 15 inch lbs. (1.7 Nm).
7. Place diaphragm rod on the pin and install the C-clip.
8. Reconnect the vacuum hose(s).