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DISTRIBUTOR REBUILD AND PIP INSTALL
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This write-up addresses a fairly common problem on 2.3's. The Profile Ignition Pickup (PIP) tends to go out, over time. This creates a no spark condition, and without fire, you're not goin' anywhere! Run codes to see if the PIP is going to be a problem. Another indication is if you're driving along on a warm summer day and the car suddenly dies for no reason. This could very well be an overheated Thick Film Ignition module (TFI). At this time, the TFI should be replaced and this is an opportune time to replace the PIP as they work in conjunction with each other.

When ordering the PIP, you'll want to go exclusively with Motorcraft parts! Ask me how I know! The Motorcraft part # is DU30C. The Ford replacement part # is E8PZ 12A112A. The best price I've found is just a hair under $40 through www.rockauto.com.

Before I pull the distributor, I set the crank pulley to TDC. Here the rotor is pointing to the #1 cylinder. I place a mark on the dizzy housing, a mark on the vane cup and a corresponding mark directly adjacent to those on the lower intake. You want to make certain that the distributor goes back in the exact same position as it came out!

Now loosen the distributor holddown bolt with a 17mm swivel socket. It can be a bear to get too 'cause the PCV hose is in the way. Use patience and perseverance and you'll get it! Now would be an excellent time to replace that bolt with a 17mm allenhead capscrew. The next time you adjust the timing, you'll be glad you did!

Disconnect the TFI connector and carefully remove the distributor. Once it's out, stuff a rag in the hole to keep contaminants out.

Give the unit a good shot with some BrakeKleen, inside and out, to clean it up some. Now begin disassembly. Pull the rotor off. Unscrew the 2 bolts that hold the vane cap on and remove it. Remove the TFI. In Ford's infinite wisdom, they designed it so you can't unbolt it with a regular socket. You can either grind down a 7/32" socket or purchase a removal tool from NAPA or Autozone for around $5.

Now remove the drive gear. Knock out the roll pin with an appropriately sized punch. Mount the unit securely in a vise and use a gear puller to remove the gear. I had an old pitman arm puller laying around but it was a little too wide.

I cut a section out of a large washer, making it sort of a horseshoe and used it to span the gap. I cranked on the puller with a socket and 1/2" ratchet and the gear came off effortlessly.

Next, unscrew the small bolt on the side of the unit that retains the octane rod. Slip the octane rod off the PIP and set it aside. Now unscrew the 2 small bolts that hold the PIP in place. Slide the PIP up and off the distributor shaft. Now slide the shaft out of the housing. There, distributor disassembled! Clean everything up and this is what you should have.

REASSEMBLY:
After everthing is cleaned, bolt the new PIP back into the housing and connect the octane rod.

Next, lightly oil the shaft with motor oil and insert it through the PIP and into the housing. Find yourself a short length of hardwood and drill a 5/16" hole about 3/4" deep. Turn the distributor upside down and insert the shaft into the hole. You want to leave a good bit of clearance between the plate that's attached to the shaft and the wood 'cause you're going to be banging on the other end of the shaft and if the plate contacts the wood, it will easily bend!

Now set the gear on the shaft and line up the roll pin holes in the gear and the shaft as close as you can.

Once you're satisfied with the alignment, slip a 9/16" deep, 1/2" drive socket onto the gear and begin tapping the gear onto the shaft. Keep everything as straight as possible so the pin holes stay aligned.

Once the gear is pressed on and aligned, insert the roll pin. NAPA has a large assortment of new roll pins. Gently begin tapping the pin in with a hammer and finish with the appropriate size punch.

Spin the shaft and make sure it turns freely in the housing with no binding. Reinstall the vane cup and rotor. Before installing the TFI, purchase the appropriate heat sink grease (Radio Shack - $2) and apply a very thin, even film to the flat portion of the housing where the TFI attaches. Install the TFI.

Replace the O-ring just above the distributor gear (NAPA has a good assortment), dunk the bottom portion of the unit in clean motor oil, reinsert the completed distributor into the hole, making sure the rotor is pointed in the exact same place it was when you removed it. Tighten the holddown with your new 17mm allenhead capscrew, fire it up, double check you timing with a timing light and you're good to go! Pretty easy, huh?!