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When ignition is in run position, the balast resistor gets extremely hot and if I run the engine, the coil and and plug/distrubutor wires also become very hot. The ignition module becomes so hot, you can't keep your hand on it.
I replaced the ignition module, coil and stator assembly in the distributor. I've run through the different ignition tests as recommended in the HAYNES repair manual including the balast resistor (wire) which read an appropriate resistance. Turning the key off, I tested the balast for continuity to a ground short to the truck body (meter beeps if the circuit is complete). I've inspected the harness throughout the engine and am convinced there are no shorts and have inspected under the dash as much as I could with out removing it or the harness completely.
Maybe I'm looking for something that doesn't need to be fixed?
Is it possible that the ignition components are expected to get that hot? Other than this, the engine runs extremely well.
It has been my experience that ballast resistors run very hot, as do coils and ignition modules. In fact, most modules have a dielectric grease applied between them and their mount, to help conduct heat away from them. As long as the truck runs OK, I wouldn't worry. Don
"Nothing lasts forever except natural stone and old Ford trucks." (Willie Nelson)
Thanks for the response Lone Ranger. My concern is that I am preparing to drive a few ten hour stretches. I know that the ignition components are fine after a few hours of travel, but I wouldn't want a wire to melt or the module to burn out after extended hours somewhere in the middle of nowhereville.
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