THUNDERBOLT IV AND V IGNITION SYSTEM - 4B-1190-823225--1 1096
1 - Distributor Cap
2 - Vent
3 - Gasket
4 - Rotor
5 - Senor Wheel
6 - Screws (5)
7 - E-Clip
8 - Shaft
9 - Screws (2)
10 - Lockwashers (2)
11 - Sensor
12 - Upper Bushing
13 - Ignition Module , If Equipped (Apply Thermalconductive
Grease)
14 - Screws (2)
15 - Distributor Housing
16 - Lockwasher
17 - Nut
18 - Lower Bushing
19 - Gasket
20 - Washer
21 - Gear
22 - Roll Pin
Disassembly
NOTICE
Refer to exploded view preceding for parts
identification during disassembly and reas-
sembly.
1. Remove rotor, sensor wheel, sensor, and ignition
module (if mounted on distributor), as previously
outlined.
2. Remove roll pin, washer and driven gear from
distributor shaft.
3. Check for side play between shaft and distributor
housing bushings. Maximum side play is .002 in.
(0.05 mm).
4. Remove shaft from housing and check shaft for
being bent with a dial indicator and V-blocks.
Maximum runout is .002 in. (0.5 mm).
Reassembly
1. Lubricate shaft with engine oil. Install E-clip (if
removed) on shaft in housing.
2. Install washer on shaft. Install original gear; slide
onto shaft and install roll pin.
IMPORTANT: Hole may be offset and gear will
only fit in one direction.
3. If installing a new gear, the gear will come drilled
on one side. Slide gear onto shaft; align hole in
gear with hole in shaft. Using these holes as
guides, drill through other side of gear with a
3/16 in. carbide tripped drill.
IMPORTANT: If a new gear has only a dimple, you
will have to drill through one side of the gear be-
fore you slide gear onto shaft. In most cases it is
recommended to have a machine shop complete
the drilling operation for new gear installation.
72735
b
c
d
a
a - Drill Press
b - 3/16 in. Carbide Tip Drill
c - V-Block
d - New Gear
4. Install sensor, sensor wheel, rotor, and ignition
module (if mounted on distributor), as previously
outlined.
5. Install distributor as outlined in “Distributor Instal-
lation.”
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