2.3L ('83-'97) Ignition Module overheating issues

[Jah-Knee]

For a 1994 2.3 manual Ranger my ignition module is overheating and has been replaced over and over with the same symptoms (starting up fine, running consistently good until all of a sudden cuts out with total loss of power and then after a short period of time will start back up until the next similar episode which might occur very soon thereafter or just after awhile) - should the ignition module be mounted on a heat sink? And should thermal paste be used instead of dielectric grease?

 

[Uncle Gump]

A heat sink certainly helps...

It is a special grease used when mounting and its not dielectric grease.

Another issue is today's parts are not the quality as they use to be. Even a good used motorcraft unit is far better then most all the aftermarkets.

 

[scotts90ranger]

I've had that before, it's not heat it's a lack of ground to the module, make a ground wire from the battery or frame or whatever is easy and put it under one of the 3 mounting bolts... believe me, that's the reason I ended up rolling my '90 Ranger, it would do exactly that, it picked exactly the wrong time to do it...

 

[Jah-Knee]

The repair shop that has tried to fix the overheating failure of the ignition module has replaced the module 6 times! They could not locate a Motorcraft one and just obtain ones from NAPA or O'Reilly's. But I managed to buy a Motorcraft module on EBay from a mechanic who swore it was in fine working condition but the repair shop said it would not start the truck and just reinstalled the aftermarket module back in. Could the repair shop have installed the Motorcraft module upsidedown by mistake? They said there was only 3 bolts used, claiming the 4th female hole was stripped. With the holes in the module being offset and not symmetrical perhaps it could have inadvertently been installed upsidedown PERHAPS and therefore would have been totally disfunctional in that position?

 

[scotts90ranger]

There are 4 holes and it's only using 3, I've heard using the 4th makes them not work or something, don't remember...

I think there is a different motorcraft module used on some '94 california models with a cam sensor, I think they're black instead of grey or something. I'm not sure if you can mount them upside down, I think the connectors are keyed different.

I would try grounding one of the screws before getting crazy, it was night and day for me, I ran with an alligator clip ground for several months and it helped...