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Distributor Overhaul: 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.


  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.
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