brodysZ28

In the past 2 years I have gone through 5 or so ignition coils all due to the same reason. The solid copper wires (seems to be the yellow one usually) snaps in half. Its under the plastic housing with no tension on it, I figured maybe from vibration. Maybe there is more to this though. The sheathing looks almost melted where the wire breaks, the wire is partially exposed where it breaks. It doesn't have any correlation with temp, rpm, speed, or any other variable that I can think of. Has this happened to anyone else or does anybody have any ideas of why it would do this?

Damon

Can't say I've had that problem. How does the cap look? Are you installing the conductive "button" and the rubber "donut" around it properly in the cap? Is the coil cover somehow pinching the wire when you put it on (there are channels the wire is supposed to sit down in molded into the cap and route through)? Do you have the armature grounding wire installed properly (the wire that goes from the metal "square" around the coil to the center terminal connector on the side of the cap)?

FYI, proper assembly order from bottom to top is: Cap, button (spring facing up towards the coil), donut (smeared with a thin coat of dielectric grease on both sides), coil, coil cover.

While I've never encountered this particular problem I can tell you that almost all "burn through" problems with ignition parts are a result of arcing on the high voltage side or a high level or resistance somewhere it should be low.

You can forget about it being vibration fatigueing and breaking the wire. That dog don't hunt.

brodysZ28

The whole distributor is just over a year old. I had this issue with at least one coil from the other distributor tho which was a stock replacement. This one is an accel unit. Both the button and the donut are in there... Once it looked like it could have been pinched. I done really set the wires into any specific channels. Check out the pics.

Maybe I should start checking resistance throughout the system? I hate electrical issues...


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