1984 Tbird 3.8L - Ignition Module Fails every 10k Miles - June 07, 2016, 07:05:09 AM Ok, bought this car with 50K miles in early 2014 (a for fun car turned into my daily driver except winter), and since I had these cars before, I replaced the module for prevention (with O'Reilly's store brand). In early 2015, began acting up (cutting out on expressway), so replaced module with Borg-Warner module (back in the 1990s, I recall have good luck with these). A few days ago, the car began sputtering and missing severely. I got a new module and runs good. Fortunately, Ive gotten these replacements under warranty, but how can I rely on a part that fails in 10,000 miles? Should I just replace it every year even if car is running well?Thanks. Quote Selected
1984 Tbird 3.8L - Ignition Module Fails every 10k Miles - Reply #1 – June 07, 2016, 07:55:47 AM Quote from: atengnr;455662Ok, bought this car with 50K miles in early 2014 (a for fun car turned into my daily driver except winter), and since I had these cars before, I replaced the module for prevention (with O'Reilly's store brand). In early 2015, began acting up (cutting out on expressway), so replaced module with Borg-Warner module (back in the 1990s, I recall have good luck with these). A few days ago, the car began sputtering and missing severely. I got a new module and runs good. Fortunately, Ive gotten these replacements under warranty, but how can I rely on a part that fails in 10,000 miles? Should I just replace it every year even if car is running well?Thanks.They fail because of the heat from the engine. If you're worried about it, maybe keep a cheap spare in the trunk? That way when it fails you can change it, and warranty the good one each time. I'm guessing it has a lifetime warranty? Quote Selected
1984 Tbird 3.8L - Ignition Module Fails every 10k Miles - Reply #2 – June 07, 2016, 11:25:58 AM Personally, I've had like 11 of these cars, personally daily driven them pretty much since I was 16, and I have never had one fail on me. I'm not saying they don't fail, I'm just saying I've never had one go bad. If you are replacing it every couple thousand miles, I seriously doubt that's the real problem. Quote Selected
1984 Tbird 3.8L - Ignition Module Fails every 10k Miles - Reply #3 – June 07, 2016, 12:34:26 PM Google "mercury cougar tfi relocation" there are kits to move it away from the heat of the engine or you can make one yourself. Quote Selected
1984 Tbird 3.8L - Ignition Module Fails every 10k Miles - Reply #4 – June 07, 2016, 01:47:25 PM I remember reading a borderline PIP can take out the TFI. Might be the case here, but that's along time for the PIP to remain borderline. You're using some kind of thermal paste between the TFI and distributor, correct? Quote Selected
1984 Tbird 3.8L - Ignition Module Fails every 10k Miles - Reply #5 – June 07, 2016, 09:18:01 PM Quote from: JeremyB;455670I remember reading a borderline PIP can take out the TFI. Might be the case here, but that's along time for the PIP to remain borderline. You're using some kind of thermal paste between the TFI and distributor, correct?Yeah, I use the stuff that the module comes with. Shoot, is that stuff not the thermal transfer paste??Yes, so the past two modules failed at 10K miles each (best I can tell as the replacement of the module made the running problem go away).Whats this about the PIP failing causing premature failure of the module??? Quote Selected
1984 Tbird 3.8L - Ignition Module Fails every 10k Miles - Reply #6 – June 08, 2016, 04:34:19 AM The pip signal runs directly through the tfi module. Might also be called a stator depending on who you ask. It is inside the base of the dist, kinda a pain to replace, but it should be replaced with the tfi whenever possible from what everyone says. Quote Selected
1984 Tbird 3.8L - Ignition Module Fails every 10k Miles - Reply #7 – June 08, 2016, 07:20:11 AM Hey, I did notice that the engine is down on power (I drive the car very gently so it takes time for me to notice acceleration issues). I did also replace the distributor cap moments after replacing the module (after starting car), but the parts store did not have a replacement rotor and the existing one had a bit of rust on the contact tip, which I brushed off with sand paper.....Could I have increased the air gap excessively (I didnt remove much off the tip, just lightly brushed)??? I did adjust timing as well that day.Thanks. Quote Selected
1984 Tbird 3.8L - Ignition Module Fails every 10k Miles - Reply #8 – June 08, 2016, 10:34:39 AM I've never replaced a PIP unless it was giving a definite issue, slap on a module and go...There was a good reason Ford began remote mounting the modules, on the dist is a lousy place as they overheat... Maybe if run on highway there is enough airflow over module to keep it cool, but puttering around town with A/C on and temps in 90s, no doubt a killer... I always keep a spare module and even complete dist in my car...I believe the 3.8 was first to use remote mounted modules... Quote Selected
1984 Tbird 3.8L - Ignition Module Fails every 10k Miles - Reply #9 – June 08, 2016, 01:29:15 PM Had an Escort with the distributor mounted module. Went through 5 modules in about 3 years. As others have stated, too much heat. Mine would fail without warning. Quote Selected
1984 Tbird 3.8L - Ignition Module Fails every 10k Miles - Reply #10 – June 08, 2016, 08:29:21 PM The module on my 3.8 was relocated to the fender apr0n when the engine was rebuilt. The owner also used a metallic based thermal compound - thermal conductivity is about 3x that of the silicone based stuff the unit comes with. That was 10 years/ 70,000 miles ago, still the same module. Quote Selected
1984 Tbird 3.8L - Ignition Module Fails every 10k Miles - Reply #11 – June 09, 2016, 05:28:21 PM I have every receipt for every repair done on my Thunderbird since it was new. It's still rocking the factory TFI at 137K miles and 28 years. I do keep a spare in the glove box just in case. Quote Selected
1984 Tbird 3.8L - Ignition Module Fails every 10k Miles - Reply #12 – June 15, 2016, 11:06:30 AM relocation of the ign module to the pass side strut tower on the 5.0 is perfect for using the existing wire harness plug in.once mounted to the heat sync you find in the bone yard you can fab up the ign module to pip / dizzy wiring.I had no idea these Ign modules get very hot on their own. Quote Selected
1984 Tbird 3.8L - Ignition Module Fails every 10k Miles - Reply #13 – June 15, 2016, 11:10:40 AM here is the link that is in my diy link belowhttp://www.foxtbirdcougarforums.com/showthread.php?37976-TFI-(ignition)-Module-relocation-JCassity-rendition Quote Selected
1984 Tbird 3.8L - Ignition Module Fails every 10k Miles - Reply #14 – June 15, 2016, 11:22:00 AM here is a pic of my dissecting the pip to understand why one failed on me.the black conductor not only ties into the pip / tif but it also bonds to chassis ground by a small tiny cad weld.so you want to make sure that you have tone or continuity from the black wire to dizzy case. Quote Selected
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