rickwrench
Famous Member
Back story:
When I originally upgraded to a 1946 and DSII ignition for the Squire, way back when, I opted for new parts where possible. I had a few original OEM blue grommet boxes in the parts pile, but used a brand new box instead.
It worked great for years (5, 6, ?).
Problem:
About two months ago I started noticing odd starting issues, bad mileage (only 20 mpg on the highway), occasional rough running and the engine sometimes cutting out on right hand turns. That last symptom screamed "carb", but the odd starting issue said otherwise... There was no firing until the key moved off the "start" position, that is, crank, crank, crank, crank, crank, and as soon as I let go of the key (key springs back to "ingnition on" position) the engine would fire up. That symptom made me think the start/retard wire might be shorting the ignition somewhere. We finally had a few dry days here, so I got my skippy suit on and started digging.
I initially thought it had to be somewhere in the wiring, but after running all the wires, the only place left the short could be was in the control box.
Solution:
I unhooked the harness and removed the box. On a hunch, I gave it a shake and, lo and behold, it sloshed! Upon further examination, the epoxy potting on the back of the unit had shrunk/cracked away from the shell and a little water would come out with vigorous shaking. The junk/soaked control box made a satisfying thud on the bottom of the garbage can.
Now that I think about it, it was a miracle it worked at all...
As mentioned, this was an after market DSII replacement box, not an original Motorcraft/Ford box.
Fortunately I was able to dig up one of the junkyard bought original OEM blue grommet box out of my "old parts" crates. The epoxy potting on the OEM box still looked new. I mounted it, plugged it in, and the car started instantly, problem solved.
Driving the car around this past week, and I'm back to 30+ highway mpg.
So, the original OEM boxes are 30+ years bullet proof, new replacement boxes are not.
Rick(wrench)
When I originally upgraded to a 1946 and DSII ignition for the Squire, way back when, I opted for new parts where possible. I had a few original OEM blue grommet boxes in the parts pile, but used a brand new box instead.
It worked great for years (5, 6, ?).
Problem:
About two months ago I started noticing odd starting issues, bad mileage (only 20 mpg on the highway), occasional rough running and the engine sometimes cutting out on right hand turns. That last symptom screamed "carb", but the odd starting issue said otherwise... There was no firing until the key moved off the "start" position, that is, crank, crank, crank, crank, crank, and as soon as I let go of the key (key springs back to "ingnition on" position) the engine would fire up. That symptom made me think the start/retard wire might be shorting the ignition somewhere. We finally had a few dry days here, so I got my skippy suit on and started digging.
I initially thought it had to be somewhere in the wiring, but after running all the wires, the only place left the short could be was in the control box.
Solution:
I unhooked the harness and removed the box. On a hunch, I gave it a shake and, lo and behold, it sloshed! Upon further examination, the epoxy potting on the back of the unit had shrunk/cracked away from the shell and a little water would come out with vigorous shaking. The junk/soaked control box made a satisfying thud on the bottom of the garbage can.
Now that I think about it, it was a miracle it worked at all...
As mentioned, this was an after market DSII replacement box, not an original Motorcraft/Ford box.
Fortunately I was able to dig up one of the junkyard bought original OEM blue grommet box out of my "old parts" crates. The epoxy potting on the OEM box still looked new. I mounted it, plugged it in, and the car started instantly, problem solved.
Driving the car around this past week, and I'm back to 30+ highway mpg.
So, the original OEM boxes are 30+ years bullet proof, new replacement boxes are not.
Rick(wrench)
