Distributor Gear - No Start/Dies on Road
84ford20Article No. 84-2-13
NO START - QUITS ON ROAD - DISTRIBUTOR GEAR - DAMAGE - 2.3L TURBO
FORD 1984 MUSTANG, T-BIRD WITH 2.3L TURBO
LINCOLN-MERCURY 1984 CAPRI WITH 2.3L TURBO
CALIBRATIONS: All 2.3L with Turbo Distributor gear and/or auxiliary shaft gear damage may be caused by possible contamination of oil pan/oil pump not apparent during visual inspection.
This article adds clean oil flush procedures to Owner Notification Program B40. The auxiliary shaft should be replaced as well as the distributor even though the auxiliary shaft does not show damage.
^ Remove the distributor and thoroughly clean the distributor hole and the distributor shaft hole and replace with the new distributor.
^ Remove and flush oil pan and oil pump (Page 36, Step 18).
^ Remove and replace auxiliary shaft even if no gear distress is visible, as follows:
FIGURE 12:
Distributor Drive Auxiliary Shaft Replacement
Removal:
1. Remove the timing mark access plug from the timing belt cover (Figure 12).
FIGURE 13:
2. Use a socket wrench on the crankshaft pulley bolt to turn the crankshaft and align the camshaft sprocket and crankshaft pulley timing marks (Figure 13).
3. Disconnect the distributor high tension lead, and remove the distributor cap and scribe or ink an index mark on the distributor housing aligned with the rotor position and remove the distributor.
4. Loosen the adjusting and pivot bolts, remove the alternator and power steering belts from the pulleys, and position the belts aside.
5. Remove the water pump pulley.
FIGURE 12:
6. Remove the timing belt outer cover, Figure 12.
7. Loosen the timing belt tensioner adjusting screw. Relieve the belt tension (move pulley away from belt) with tool #T74P-6254-A, or equivalent, and retighten adjusting screw.
8. Remove the timing belt.
FIGURE 14:
9. Remove the sprocket bolt, washer and sprocket from the auxiliary shaft. Use tool T74P-6256-B to
hold the sprocket while removing the sprocket bolt.
10. Remove the auxiliary shaft cover (3 screws), using a screwdriver to pry or slide it out from under the timing belt inner cover.
FIGURE 15:
11. Inspect the gasket between the timing belt inner cover and cylinder block for damage; i.e., tears or cuts. If the gasket is damaged, remove the belt tensioner, cover attaching screws and timing belt inner cover. Carefully cut the gasket along the cylinder front cover (Figure 15), and remove the gasket. Using the cut-off gasket as a template, cut out a new gasket.
12. Remove the auxiliary shaft retaining plate (2 screws).
13. Carefully pull the auxiliary shaft out of the crankcase.
Installation:
1. Install new distributor after dipping distributor shaft in D9AZ-19579-C oil conditioner.
2. If necessary, install drive pin (385803-S) in auxiliary shaft. In most parts kits the pin will already be installed. See removed shaft for proper location. Installed dimension is 29.59 mm (1.165 inches) from exposed end of pin to opposite side of hub.
3. Dip auxiliary shaft (E4ZE-6K230-AA) into D9AZ- 19579-C oil conditioner prior to installation.
4. Install auxiliary shaft retaining plate (2) screws. (8-12 N-m - 6-9 lb.ft.).
5. If gasket is to be replaced, clean gasket surface of cover and cylinder block and install new gasket.
6. Install auxiliary shaft cover (3) screws (8-12 N-m - 6-9 lb.ft.).
NOTE: If the timing belt inner cover was not removed, slide the auxiliary cover under the belt inner cover and align the screw holes.
7. If the timing belt inner cover was removed to replace gasket, install it with gasket and tighten bolts to specification.
a. Inner timing belt cover a stud (2 required) 19-28 N-m (14-21 lbs.ft.)
b. Belt tensioner (pivot bolt) 38-54 N-m (28-40 lbs.ft.).
c. Belt tensioner (adjusting bolt) 19-28 N-m (14-21 lbs.ft.).
8. Install auxiliary shaft sprocket and torque the attaching bolt to 38-54 N-m (28-40 lbs.ft.). Hold the sprocket with tool T74P-6256-B while tightening the sprocket bolt.
FIGURE 13:
9. Scribe the rotor index mark on the new distributor housing. Align the distributor rotor with the index marked on the distributor housing. Check the crankshaft and camshaft timing marks to be sure they are aligned (see Figure 13). Position the timing belt over the sprockets, keeping the belt taut between crankshaft, auxiliary shaft and camshaft sprockets on left side of engine as shown in Figure 13.
10. Release the timing belt tensioner against the timing belt, and torque timing belt tensioner.
a. Pivot bolt, 8-12 N-m (6-9 lb.ft.).
b. Adjusting bolt, 19-28 N-m (14-21 lb.ft.).
NOTE: Recheck the timing marks alignment (Figure 13) and index belt if necessary.
11. Rotate engine crankshaft two complete revolutions to seat the timing belt.
12. Recheck timing marks, and inspect the belt tensions.
a. Check marks on crankshaft pulley and timing indicator.
b. Through timing window plug hole on outer cover.
c. Rotor alignment at the distributor (index marked in Step 3, Removal).
13. Install timing belt outer cover and bolts (8-12 N-m - 6-9 lb.ft.).
14. Install front cover timing window plug.
15. Install water pump pulley and torque (4) bolts. (17-25 N-m - 14-20 ft.lbs.).
16. Install the alternator and power steering belts and adjust tension to specifications (alternator belt tension 110-130 lbs., power steering belt tension 110-130 lbs.). Torque the pivot and adjusting bolts to specification.
Alternator pivot bolt torque, 60-79 N-m (45-57 lb.ft.) Alternator adjusting bolt torque, 33-46 N-m (24-34 lb.ft.) Power steering pivot bolt torque, 33-46 N-m (24-34 lb.ft.) Power steering adjusting bolt torque, 33-46 N-m (24-34 lb.ft.)
17. Install the distributor cap, and connect the high tension lead.
18. Oil Pan, Oil Pump, Oil Filter Removal and Cleaning Procedures
Removal:
a. Remove oil pan
b. Remove oil pump
c. Remove pick-up tube and screen assembly
d. Clean and flush all components internally as well as externally
Installation:
a. Reassemble oil pump and attach pick-up tube and screen
b. Install oil pump (19.0-29.0 N-m) (14-21 ft.lbs.)
c. Install oil pan (torque in proper sequence)
d. Install new oil filter (10.7-14.1 N-m) (95-125 in.lbs.)
e. Check oil fluid level
NOTE: THE ABOVE CLEANING PROCEDURES SHOULD BE USED ON ANY 2.3L TURBO AS REQUIRED.
19. Connect battery cable.
20. Start engine and check operation.
21. Check and adjust base engine timing as described below. To check base timing, disconnect the spark output trigger circuit 324 (yellow/light green dot wire) at the single wire black connector. This locks the TFI module into "no advance" and allows adjustment of initial timing to the required 10~ BTDC. The timing procedure is also shown on the Vehicle Emission Control Information label attached to the underside of the engine hood.
Change engine code on code tag (attached to front of engine near bottom of timing belt outer cover) to 3G975-BA, using an indelible black ink Magic Marker or Sharpie #59 pen.
22. Remove protective cover.
23. Close hood.
PART NUMBER PART NAME CLASS
E4FZ-6A739-A Auxiliary Shaft B
E3ZZ-12127-B Distributor C
* -Available at Parts Distribution Center after 1-27-84.
OTHER APPLICABLE ARTICLES: Owner Notification Program B40
WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual.
OPERATION: SPONB4083B
TIME: 2.9 Hrs. DLR. CODING: Basic Part No. 6600 Code: 49